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Yamaha XMAX 125, Service Manual

The Yamaha XMAX 125 Service Manual is a comprehensive guide for owners, containing in-depth instructions on maintenance, repairs, and troubleshooting. Available for free download at manualshive.com, this essential manual ensures that every XMAX 125 owner can confidently maintain and service their scooter with ease and efficiency.

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ENGINE REMOVAL (YP250R)

5-66

TIP

Tighten the muffler mounting bolts in the proper 
tightening sequence as shown.

7. Tighten:

• Exhaust pipe nuts

8. Tighten:

• Muffler joint bolt
• O

2

 sensor

T

 

R

.

.

 

Exhaust pipe nut

20 Nm (2.0 m·kgf, 14 ft·lbf)

T

 

R

.

.

 

Muffler joint bolt

14 Nm (1.4 m·kgf, 10 ft·lbf)

O

2

 sensor

45 Nm (4.5 m·kgf, 32 ft·lbf)

2

3

1

Summary of Contents for XMAX 125

Page 1: ...SERVICE MANUAL 2010 37P F8197 E0 YP125R YP250R ...

Page 2: ...0R 2010 SERVICE MANUAL 2009 by Yamaha Motor España S A First edition November 2009 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor España S A is expressly prohibited ...

Page 3: ...nificant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable TIP Designs and specifications are subject to change without notice EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations This is the safety alert ...

Page 4: ...ub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction ch...

Page 5: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ...OF THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 8 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 CHECKING THE CONNECTIONS 1 10 SPECIAL TOOLS 1 11 ...

Page 10: ...ICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the frame EAS20150 MODEL LABEL The model label 1 is affixed to the location shown This information will be needed to order spare parts 1 1 ...

Page 11: ...requirements for the engine to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the ...

Page 12: ...led by the ECU Signals that are input from the throttle position sensor coolant temperature sensor lean angle sensor crankshaft position sensor in take air pressure sensor intake air temperature sensor speed sensor and O2 sensor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor As a result the volume of fue...

Page 13: ...ion display will appear and then disappear in order to test the electrical circuit Odometer and tripmeter modes Pushing the SELECT button switches the dis play between the odometer mode Odo and the tripmeter modes Trip in the following order Odo Trip top Trip bottom Trip top Odo Trip top When approximately 1 7 L 0 45 US gal 0 37 Imp gal of fuel remains in the fuel tank the bot tom segment of the f...

Page 14: ...with changes in the weather and engine load If the top segment and coolant temperature warning indicator flash stop the vehicle and let the en gine cool NOTICE ECA37P1034 Do not continue to operate the engine if it is overheating Oil change indicator OIL This indicator flashes at the initial 1000 km 600 mi then at 6000 km 3500 mi and every 6000 km 3500 mi thereafter for YP125R or at 4000 km 2500 m...

Page 15: ...re placement indicator comes on i e before the V belt replacement interval has been reached the indicator must be reset after the V belt replace ment for the next periodic V belt replacement to be indicated at the correct time Self diagnosis device This model is equipped with a self diagnosis de vice for various electrical circuits If a problem is detected in any of those circuits the multi functi...

Page 16: ...t flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Ambient temperature display Pushing the SELECT button for at least two seconds switches the clock display to the ambi ent temperature display This display shows the ambient temperature from 10 C to 50 C in 1 C increments The temperature displayed may vary from the ambient temperatu...

Page 17: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 18: ...rease Oil bearings liberally when installing if appropriate NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned op...

Page 19: ...ral times 3 Check All connections Loose connection Connect properly TIP If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector TIP Make sure all connections are tight 5 Check Continuity with the pocket tester TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at m...

Page 20: ...id any mistakes TIP For U S A and Canada use part numbers starting with YM YU or ACC For others use part numbers starting with 90890 Tool name Tool No Illustration Reference pages Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 10 8 75 8 76 8 77 8 80 8 81 8 82 8 83 8 84 8 85 8 86 8 87 8 89 8 90 8 91 Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 3 7 3 22 FI diagnostic ...

Page 21: ...dle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 52 4 54 Fork seal driver weight 90890 01367 Replacement hammer YM A9409 7 4 54 Fork seal driver attachment ø38 90890 01372 Replacement 38 mm YM A5142 1 4 54 Yamaha bond No 1215 90890 85505 Three Bond No 1215 5 12 5 43 5 59 5 103 5 120 6 15 Tool name Tool No Illustration Reference pages YM 01300 YM A9409 7 YM A5142 4 ...

Page 22: ...lve guide installer ø4 5 90890 04117 Valve guide installer 4 5 mm YM 04117 5 20 Valve guide reamer ø4 5 90890 04118 Valve guide reamer 4 5 mm YM 04118 5 20 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 26 5 85 Rotor holding tool 90890 01235 Universal magneto rotor holder YU 01235 5 33 5 38 5 93 5 98 Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 33 5 37 5 41 5 42 5 4...

Page 23: ... 5 94 5 97 Clutch spring holder arm 90890 01464 5 34 5 37 5 94 5 97 Oil seal guide ø41 90890 01396 5 36 5 96 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 41 5 101 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 5 46 5 106 8 88 Tool name Tool No Illustration Reference pages ...

Page 24: ...5 58 5 59 5 119 5 120 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 58 5 59 5 119 5 120 Adapter M14 90890 01478 Adapter 6 YM 90066 5 58 5 59 5 119 Fork seal driver attachment 90890 01186 Replacement 27 mm YM A9409 1 5 58 Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 74 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 25: ... 5 79 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 79 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 79 Yamaha grease G 90793 40016 5 91 Spacer crankshaft installer 90890 04081 Pot spacer YM 91044 5 119 Tool name Tool No Illustration Reference pages YU 01083 3 YM 91044 ...

Page 26: ...890 04058 Bearing driver 40 mm YM 04058 6 6 6 15 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 15 Fuel sender wrench 90890 11098 7 3 7 4 Pressure gauge 90890 03153 YU 03153 7 4 Fuel pressure adapter 90890 03181 7 4 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 83 Tool name Tool No Illustration Reference pages ø10 ø30 ...

Page 27: ...SPECIAL TOOLS 1 18 Test harness lean angle sensor 6P 90890 03209 8 84 Test harness 90890 03204 8 89 Tool name Tool No Illustration Reference pages ...

Page 28: ...SPECIAL TOOLS 1 19 ...

Page 29: ...AND LUBRICANT TYPES YP125R 2 21 ENGINE 2 21 CHASSIS 2 23 LUBRICATION SYSTEM DIAGRAMS YP125R 2 25 COOLING SYSTEM DIAGRAMS YP125R 2 27 CABLE ROUTING YP125R 2 29 GENERAL SPECIFICATIONS YP250R 2 47 ENGINE SPECIFICATIONS YP250R 2 48 CHASSIS SPECIFICATIONS YP250R 2 56 ELECTRICAL SPECIFICATIONS YP250R 2 59 TIGHTENING TORQUES YP250R 2 62 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 62 ENGINE TIGHTENING TORQ...

Page 30: ...COOLING SYSTEM DIAGRAMS YP250R 2 73 CABLE ROUTING YP250R 2 75 ...

Page 31: ......

Page 32: ...9D3 MBK Dimensions Overall length 2201 mm 86 7 in Overall width 776 mm 30 6 in Overall height 1337 mm 52 6 in Seat height 792 mm 31 2 in Wheelbase 1545 mm 60 8 in Ground clearance 134 mm 5 30 in Minimum turning radius 1805 mm 71 1 in Weight With oil and fuel 171 6 kg 378 lb Maximum load 186 kg 410 lb ...

Page 33: ...grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 1 60 L 1 69 US qt 1 41 Imp qt Without oil filter element replacement 1 40 L 1 48 US qt 1 23 Imp qt With oil filter element replacement 1 50 L 1 59 US qt 1 32 Imp qt Final transmission oil Type SAE 10W 30 type SE motor oil Quantity 0 21 L 0 22 US qt 0 18 Imp qt Quantity disassembled 0 23 L 0 24 US qt 0 20 Imp qt O...

Page 34: ...pump Reduction ratio 16 38 0 42 Impeller shaft tilt limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK CPR9EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 9 90 10 50 cm 0 60 0 64 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 30 225 30 325 mm 1 1900 1 1939 in Limit 30 125 mm 1 1860 in Intake B 25 064 25 164...

Page 35: ... clearance cold Intake 0 10 0 14 mm 0 0039 0 0055 in Exhaust 0 22 0 26 mm 0 0087 0 0102 in Valve dimensions Valve head diameter A intake 19 40 19 60 mm 0 7638 0 7717 in Valve head diameter A exhaust 16 90 17 10 mm 0 6654 0 6732 in Valve face width B intake 1 680 2 120 mm 0 0661 0 0835 in Valve face width B exhaust 1 480 2 190 mm 0 0583 0 0862 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433...

Page 36: ...er head valve seat width intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Cylinder head valve seat width exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve spring Free length intake 41 71 mm 1 64 in Limit 39 62 mm 1 56 in Free length exhaust 41 71 mm 1 64 in Limit 39 62 mm 1 56 in Installed length intake 35 30 mm 1 39 in Installed length exhaust 35 30 mm 1 39 in Spring rate ...

Page 37: ...7 in Offset direction Intake side Piston pin bore inside diameter 14 002 14 013 mm 0 5513 0 5517 in Limit 14 043 mm 0 5529 in Piston pin outside diameter 13 995 14 000 mm 0 5510 0 5512 in Limit 13 975 mm 0 5502 in Piston pin to piston pin bore clearance 0 002 0 018 mm 0 0001 0 0007 in Limit 0 068 mm 0 0027 in Piston ring Top ring Ring type Barrel Dimensions B T 0 80 1 90 mm 0 03 0 07 in End gap in...

Page 38: ...ch Clutch type Dry centrifugal automatic Automatic centrifugal clutch Clutch shoe thickness 2 0 mm 0 08 in Limit 1 0 mm 0 04 in Clutch shoe spring free length 33 0 mm 1 30 in Clutch housing inside diameter 135 0 mm 5 31 in Limit 135 5 mm 5 33 in Compression spring free length 112 0 mm 4 41 in Limit 106 4 mm 4 19 in Weight outside diameter 20 0 mm 0 79 in Limit 19 5 mm 0 77 in Clutch in revolution ...

Page 39: ...r Input voltage at idle 5 V Output voltage at idle 0 40 0 90 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Ω at 20 C 68 F Intake air pressure sensor output voltage 3 57 3 71 V Intake air temperature sensor resistance 2 21 2 69 kΩ at 20 C 68 F Coolant temperature sensor resistance 2 32 2 59 kΩ at 20 C 68 F 310 326 Ω at 80 C 176 F Idling condition Engine idling speed 1600 180...

Page 40: ...Lateral wheel runout limit 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70 15 M C 56P PIRELLI 120 70 15 M C 56S MICHELIN Manufacturer model MICHELIN GOLD STANDARD PIRELLI GTS23 Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 140 70 14 M C 68P PIRELLI 140 70 14 M C 68S MICHELIN Manufacturer model MICHELIN GOLD STANDARD PIRELLI GTS24 Wear lim...

Page 41: ...ing thickness outer 7 3 mm 0 29 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 11 0 mm 0 43 in Caliper cylinder inside diameter 32 00 mm 2 1 26 in 2 Recommended fluid DOT 4 Steering Steering bearing type Ball and angular bearings Center to lock angle left 57 0 Center to lock angle right 57 0 No size of steel balls Upper 14 pcs Lower 18 pcs Front suspension Type Telescopic fork Spring shoc...

Page 42: ...lled length 241 3 mm 9 50 in Spring rate K1 8 00 N mm 0 82 kgf mm 45 68 lb in Spring rate K2 17 30 N mm 1 76 kgf mm 98 78 lb in Spring stroke K1 0 47 5 mm 0 1 87 in Spring stroke K2 47 5 95 0 mm 1 87 3 74 in Optional spring available No Spring preload adjusting positions Minimum 1 Standard 2 Maximum 4 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 ...

Page 43: ...AC magneto Standard output 14 0 V 245 W 5000 r min Stator coil resistance 0 28 0 42 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 25 0 A Rectifier capacity DC 18 0 A Withstand voltage 200 0 V Battery Model GTX9 BS Voltage capacity 12 V 8 0 Ah Manufacturer GS Headlight Bulb type Halogen bulb Bulb voltage wattage qu...

Page 44: ... in Limit 16 6 mm 0 65 in Mica undercut depth 1 35 mm 0 05 in Starter relay Amperage 180 0 A Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Coil resistance 1 4 Ω at 20 C 68 F Performance 105 118 dB 2m Turn signal relay Relay type Full transistor Built in self canceling device No Turn signal flashing frequency 75 95 cycles min Wattage 21 W 2 0 3 4 W Fuel sender unit Sender unit resistanc...

Page 45: ...ELECTRICAL SPECIFICATIONS YP125R 2 14 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 5 0 A Spare fuse 7 5 A ...

Page 46: ...is manual To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm ...

Page 47: ...ance adjusting screw locknut M5 4 7 Nm 0 7 m kgf 5 1 ft lbf Coolant drain bolt cylinder M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case cover bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf V belt case bolt M6 8 10 Nm 1 0 m kgf 7 2 ft lbf V belt case air duct bolt M6 3 7 Nm 0 7 m kgf 5 1 ft lbf Primary sheave nut M12 1 55 Nm 5 5 m kgf 40 ft lbf Secondary sheave nut M14 1 60 Nm 6 0 m kgf 43 ft lbf Clutch carrier nu...

Page 48: ...olt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing cover bolt M6 5 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing plate 1 bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Fuel injector assembly bolt M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Fuel injector assembly holder bolt M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Intake air pressure sensor bolt M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Intake air pressure sensor brack et bolt M6 1 10...

Page 49: ... lbf Mudguard bolt M6 3 11 Nm 1 1 m kgf 8 0 ft lbf Rear fender bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front cowling assembly bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Battery box bolt M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Battery holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Battery bracket bolt M8 4 30 Nm 3 0 m kgf 22 ft lbf Windshield bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Windshield bracket bolt M6 2 10 Nm ...

Page 50: ... kgf 7 2 ft lbf Grip end M16 2 26 Nm 2 6 m kgf 19 ft lbf Steering stem nut M20 1 120 Nm 12 0 m kgf 85 ft lbf Upper ring nut M25 1 75 Nm 7 5 m kgf 54 ft lbf See TIP Lower ring nut initial tightening torque M25 1 38 Nm 3 8 m kgf 27 ft lbf See TIP Lower ring nut final tightening torque M25 1 22 Nm 2 2 m kgf 16 ft lbf See TIP Speed sensor lead holder brack et bolt M6 1 9 Nm 0 9 m kgf 6 5 ft lbf Lower ...

Page 51: ... both ring nuts and then install the lock washer 5 Hold the lower and center ring nuts and then tighten the upper ring nut 75 Nm 7 5 m kgf 54 ft lbf with a torque wrench and the steering nut wrench TIP Swingarm mounting bolt 1 Temporarily install the rear wheel axle nut 1 2 Temporarily install the swingarm mounting bolt upper side 2 then the swingarm mounting bolt lower side 3 3 Tighten the rear w...

Page 52: ...ke and exhaust Valve stem ends intake and exhaust Rocker arm shaft and rocker arm Decompressor cam Oil pump driven gear shaft Oil pump rotors inner and outer Collar clutch housing Starter clutch idle gear thrust surface Starter clutch idle gear shaft surface Starter clutch gear thrust surface Starter clutch gear inner surface Starter clutch rollers Main axle thrust surface Drive axle serration Oil...

Page 53: ...LUBRICATION POINTS AND LUBRICANT TYPES YP125R 2 22 Timing chain tensioner bolt Yamaha bond No 1215 Lubrication point Lubricant ...

Page 54: ...ng point and metal to metal moving parts Rear brake pad pin Throttle cable end Throttle grip inner surface and throttle cables Handlebar grip inner surface Rubber adhesive Sidestand pivoting point and metal to metal moving parts Sidestand spring hook metal to metal moving parts Centerstand shaft pivoting point and metal to metal moving parts Centerstand spring hook metal to metal moving parts Pass...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES YP125R 2 24 ...

Page 56: ...LUBRICATION SYSTEM DIAGRAMS YP125R 2 25 EAS37P1139 LUBRICATION SYSTEM DIAGRAMS YP125R 1 2 3 4 5 3 ...

Page 57: ...LUBRICATION SYSTEM DIAGRAMS YP125R 2 26 1 Camshaft 2 Crankshaft 3 Oil pump 4 Oil filter 5 Oil strainer ...

Page 58: ...COOLING SYSTEM DIAGRAMS YP125R 2 27 EAS37P1128 COOLING SYSTEM DIAGRAMS YP125R B A B A 4 3 3 2 2 1 3 4 5 2 6 7 6 ...

Page 59: ...COOLING SYSTEM DIAGRAMS YP125R 2 28 1 Coolant reservoir 2 Coolant reservoir hose 3 Radiator cap 4 Radiator filler hose 5 Radiator 6 Radiator inlet hose 7 Radiator outlet hose ...

Page 60: ...CABLE ROUTING YP125R 2 29 EAS37P1129 CABLE ROUTING YP125R Battery front view A B C D E F G H 1 1 2 2 3 3 4 5 6 7 8 8 9 9 10 10 11 11 15 12 15 14 13 17 16 13 ...

Page 61: ...y lead to the front of the starter relay C Route the self diagnosis signal lead along the negative battery lead D Route the negative battery lead to the rear of the turn signal hazard relay lead lean angle sensor lead and headlight lead E Route the turn signal hazard relay lead to the rear of the lean angle sensor F Point the end of the plastic locking tie forward and then cut off the excess end o...

Page 62: ...CABLE ROUTING YP125R 2 31 Front fork front view A 1 1 1 1 2 2 2 3 4 5 6 7 ...

Page 63: ...ont brake hose 3 Rectifier regulator 4 Left front turn signal light coupler 5 Wire harness 6 Horn 7 Right front turn signal light coupler A Point the end of the plastic locking tie forward and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 64: ...CABLE ROUTING YP125R 2 33 Front brake hose right side view B 1 1 2 3 4 5 6 7 7 8 8 8 8 8 8 8 9 10 11 11 11 12 13 13 14 A C ...

Page 65: ...arness 9 Rear brake pipe 10 Horn leads 11 Starter motor lead 12 Headlight relay 13 Rear brake hose 14 Throttle cables A Position the plastic locking tie above the frame cross member B Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in C Point the end of the plastic locking tie forward and then cut off the excess end of the tie to 0 ...

Page 66: ...CABLE ROUTING YP125R 2 35 Engine right side view A 7 3 2 2 2 1 3 4 5 6 7 ...

Page 67: ... lock cable 2 Wire harness 3 Ignition coil lead 4 Spark plug cap 5 O2 sensor 6 Starter motor lead 7 Rear brake hose A Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 68: ...CABLE ROUTING YP125R 2 37 Throttle cables left side view A B C I J 1 2 3 3 3 4 5 5 5 6 6 6 6 6 7 7 8 9 10 11 12 13 14 14 15 16 17 17 D D E F H H G ...

Page 69: ...the rear brake pipe B Route the sidestand switch lead to the inside of the frame C Route the sidestand switch lead to the outside of the frame D Position the connector cover as shown in the illustration E Forward F Fasten the wire harness at the white tape with the holder G Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in H Point ...

Page 70: ...CABLE ROUTING YP125R 2 39 Engine left side view 2 1 3 4 A 3 ...

Page 71: ... 2 40 1 Wire harness 2 Intake air temperature sensor 3 Seat lock cable 4 Left tail brake light assembly A Point the end of the plastic locking tie to the left and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 72: ...CABLE ROUTING YP125R 2 41 Handlebar top view A 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ...

Page 73: ...el pump coupler 7 Fuel sender coupler 8 Fuel hose 9 Left handlebar switch lead 10 Rear brake hose 11 ECU engine control unit 12 Positive battery lead 13 Negative battery lead 14 Fuse box 1 15 Fuse box 2 16 Battery 17 Turn signal hazard relay A Point the end of the plastic locking tie to the left and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 74: ...CABLE ROUTING YP125R 2 43 Throttle body top view 3 1 3 4 6 10 11 9 2 2 2 3 3 C B A 18 17 13 15 16 12 11 14 3 5 7 8 10 11 12 16 15 7 19 4 ...

Page 75: ...or lead 12 Thermostat inlet hose 13 Intake air pressure lead 14 Fuel injector lead 15 Throttle position sensor lead 16 Coolant temperature sensor lead 17 ISC idle speed control unit lead 18 O2 sensor lead 19 Throttle body A Route the seat lock cable to the inside of the frame B Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in C Fa...

Page 76: ...CABLE ROUTING YP125R 2 45 Tail brake light top view 2 1 3 4 B A 1 5 6 ...

Page 77: ...rake light assembly coupler 5 Left tail brake light assembly coupler 6 Seat lock cable A Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in B Route the license plate light lead between the water guard and the license plate light bracket ...

Page 78: ...HA Dimensions Overall length 2201 mm 86 7 in Overall width 776 mm 30 6 in Overall height 1337 mm 52 6 in Seat height 792 mm 31 2 in Wheelbase 1545 mm 60 8 in Ground clearance 134 mm 5 30 in Minimum turning radius 1805 mm 71 1 in Weight With oil and fuel 177 4 kg 391 lb Maximum load 186 kg 410 lb ...

Page 79: ...E 20W 50 Recommended engine oil grade API service SF SG type or higher JASO standard MA Engine oil quantity Total amount 1 50 L 1 59 US qt 1 32 Imp qt Periodic oil change 1 30 L 1 37 US qt 1 14 Imp qt Final transmission oil Type SAE 10W 30 type SE motor oil Quantity 0 25 L 0 26 US qt 0 22 Imp qt Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearan...

Page 80: ...t limit 0 15 mm 0 0059 in Spark plug s Manufacturer model NGK DPR8EA 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Cylinder head Volume 21 40 22 00 cm 1 31 1 34 cu in Warpage limit 0 05 mm 0 0020 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 37 051 37 151 mm 1 4587 1 4626 in Limit 36 950 mm 1 4547 in Intake B 30 074 30 174 mm 1 1840 1 1880 in Limit 29 974 mm 1 1801 in Ex...

Page 81: ...head diameter A intake 33 90 34 10 mm 1 3346 1 3425 in Valve head diameter A exhaust 28 40 28 60 mm 1 1181 1 1260 in Valve face width B intake 3 394 3 960 mm 0 1336 0 1559 in Valve face width B exhaust 3 394 3 960 mm 0 1336 0 1559 in Valve seat width C intake 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve seat width C exhaust 0 90 1 10 mm 0 0354 0 0433 in Limit 1 6 mm 0 06 in Valve margi...

Page 82: ...10 mm 1 42 in Free length exhaust 38 10 mm 1 50 in Limit 36 10 mm 1 42 in Installed length intake 30 10 mm 1 19 in Installed length exhaust 30 10 mm 1 19 in Spring rate K1 intake 10 29 N mm 1 05 kgf mm 58 75 lb in Spring rate K2 intake 13 37 N mm 1 36 kgf mm 76 34 lb in Spring rate K1 exhaust 10 29 N mm 1 05 kgf mm 58 75 lb in Spring rate K2 exhaust 13 37 N mm 1 36 kgf mm 76 34 lb in Installed com...

Page 83: ...g direction exhaust Clockwise Cylinder Bore 69 000 69 005 mm 2 7165 2 7167 in Wear limit 69 100 mm 2 7205 in Taper limit 0 030 mm 0 0012 in Out of round limit 0 030 mm 0 0012 in Warp limit 0 05 mm 0 0020 in Piston Piston to cylinder clearance 0 020 0 040 mm 0 0008 0 0016 in Limit 0 15 mm 0 0059 in Diameter D 68 965 68 980 mm 2 7152 2 7157 in Height H 5 0 mm 0 20 in Offset 0 50 mm 0 0197 in Offset ...

Page 84: ...e clearance 0 030 0 070 mm 0 0012 0 0028 in Limit 0 130 mm 0 0051 in Oil ring Dimensions B T 1 50 2 50 mm 0 06 0 10 in End gap installed 0 20 0 70 mm 0 0079 0 0276 in Ring side clearance 0 060 0 150 mm 0 0024 0 0059 in Crankshaft Width A 59 75 59 80 mm 2 352 2 354 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 850 mm 0 0138 0 0335 in Big end radial clearance E 0 010 0 025 mm...

Page 85: ... 14 2 857 Operation Centrifugal automatic type Gear ratio 2 440 0 830 1 Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Output pressure 250 0 kPa 2 50 kgf cm 36 3 psi Fuel injector Model quantity 1C04 1 Throttle body Type quantity EFI 1C04 1 ID mark 1C04 00 Throttle position sensor Input voltage at idle 5 V Output voltage at idle 0 40 0 90 V Fuel injection sen...

Page 86: ...ENGINE SPECIFICATIONS YP250R 2 55 Water temperature 85 0 95 0 C 185 00 203 00 F Oil temperature 75 0 85 0 C 167 00 185 00 F Throttle cable free play 3 0 5 0 mm 0 12 0 20 in ...

Page 87: ...ateral wheel runout limit 0 5 mm 0 02 in Wheel axle bending limit 0 25 mm 0 01 in Front tire Type Tubeless Size 120 70 15 M C 56P PIRELLI 120 70 15 M C 56S MICHELIN Manufacturer model MICHELIN GOLD STANDARD PIRELLI GTS23 Wear limit front 1 6 mm 0 06 in Rear tire Type Tubeless Size 140 70 14 M C 68P PIRELLI 140 70 14 M C 68S MICHELIN Manufacturer model MICHELIN GOLD STANDARD PIRELLI GTS24 Wear limi...

Page 88: ...ing thickness outer 5 3 mm 0 21 in Limit 0 8 mm 0 03 in Master cylinder inside diameter 11 0 mm 0 43 in Caliper cylinder inside diameter 22 22 mm 2 0 87 in 2 Recommended fluid DOT 4 Steering Steering bearing type Ball and angular bearings Center to lock angle left 57 0 Center to lock angle right 57 0 No size of steel balls Upper 14 pcs Lower 18 pcs Front suspension Type Telescopic fork Spring shoc...

Page 89: ...lled length 241 3 mm 9 50 in Spring rate K1 8 00 N mm 0 82 kgf mm 45 68 lb in Spring rate K2 17 30 N mm 1 76 kgf mm 98 78 lb in Spring stroke K1 0 47 5 mm 0 1 87 in Spring stroke K2 47 5 95 0 mm 1 87 3 74 in Optional spring available No Spring preload adjusting positions Minimum 1 Standard 2 Maximum 4 Swingarm Swingarm end free play limit radial 1 0 mm 0 04 in Swingarm end free play limit axial 1 ...

Page 90: ...C magneto Standard output 14 0 V 260 W 5000 r min Stator coil resistance 0 32 0 48 Ω at 20 C 68 F Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1 14 9 V Rectifier capacity 25 0 A Rectifier capacity DC 18 0 A Withstand voltage 200 0 V Battery Model GTX9 BS Voltage capacity 12 V 8 0 Ah Manufacturer GS Headlight Bulb type Halogen bulb Bulb voltage wattage qua...

Page 91: ...t 22 4 mm 0 88 in Mica undercut depth 1 00 mm 0 04 in Starter relay Amperage 180 0 A Horn Horn type Plane Quantity 1 pc Maximum amperage 3 0 A Coil resistance 1 4 Ω at 20 C 68 F Performance 105 118 dB 2m Turn signal relay Relay type Full transistor Built in self canceling device No Turn signal flashing frequency 75 95 cycles min Wattage 21 W 2 0 3 4 W Fuel sender unit Sender unit resistance full 2...

Page 92: ...ELECTRICAL SPECIFICATIONS YP250R 2 61 Spare fuse 15 0 A Spare fuse 10 0 A Spare fuse 5 0 A Spare fuse 7 5 A ...

Page 93: ... manual To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kgf ft lbf 10 mm 6 ...

Page 94: ...43 ft lbf Camshaft retainer bolt M6 2 8 Nm 0 8 m kgf 5 8 ft lbf Valve clearance adjusting screw locknut M6 2 14 Nm 1 4 m kgf 10 ft lbf V belt case cover bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf V belt case cover screw M6 3 7 Nm 0 7 m kgf 5 1 ft lbf V belt case bolt M6 11 10 Nm 1 0 m kgf 7 2 ft lbf Primary sheave nut M14 1 80 Nm 8 0 m kgf 58 ft lbf Secondary sheave nut M14 1 60 Nm 6 0 m kgf 43 ft lbf Se...

Page 95: ...g bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Water pump housing cover bolt M6 2 10 Nm 1 0 m kgf 7 2 ft lbf Coolant drain bolt water pump M6 1 10 Nm 1 0 m kgf 7 2 ft lbf Water pump outlet pipe bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Fuel injector assembly bolt M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Fuel injector assembly holder bolt M6 1 12 Nm 1 2 m kgf 8 7 ft lbf Intake air pressure sensor bolt M6 2 10 Nm 1 0 m kg...

Page 96: ...TIGHTENING TORQUES YP250R 2 65 Cylinder head tightening sequence Muffler tightening sequence 2 3 1 ...

Page 97: ...lbf Mudguard bolt M6 3 11 Nm 1 1 m kgf 8 0 ft lbf Rear fender bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Front cowling assembly bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Battery box bolt M6 1 11 Nm 1 1 m kgf 8 0 ft lbf Battery holder bolt M6 1 7 Nm 0 7 m kgf 5 1 ft lbf Battery bracket bolt M8 4 30 Nm 3 0 m kgf 22 ft lbf Windshield bracket bolt M6 2 7 Nm 0 7 m kgf 5 1 ft lbf Windshield bracket bolt M6 2 10 Nm 1...

Page 98: ... Nm 1 0 m kgf 7 2 ft lbf Grip end M16 2 26 Nm 2 6 m kgf 19 ft lbf Steering stem nut M20 1 120 Nm 12 m kgf 85 ft lbf Upper ring nut M25 1 75 Nm 7 5 m kgf 54 ft lbf See TIP Lower ring nut initial tightening torque M25 1 38 Nm 3 8 m kgf 27 ft lbf See TIP Lower ring nut final tightening torque M25 1 22 Nm 2 2 m kgf 16 ft lbf See TIP Speed sensor lead holder brack et bolt M6 1 9 Nm 0 9 m kgf 6 5 ft lbf...

Page 99: ... both ring nuts and then install the lock washer 5 Hold the lower and center ring nuts and then tighten the upper ring nut 75 Nm 7 5 m kgf 54 ft lbf with a torque wrench and the steering nut wrench TIP Swingarm mounting bolt 1 Temporarily install the rear wheel axle nut 1 2 Temporarily install the swingarm mounting bolt upper side 2 then the swingarm mounting bolt lower side 3 3 Tighten the rear w...

Page 100: ...amshaft lobes Valve stems intake and exhaust Valve stem ends intake and exhaust Rocker arm shafts Rocker arm inner surface Impeller shaft gear Oil pump shaft Oil pump rotors inner and outer Oil pump gasket Engine mounting collars Starter clutch idle gear thrust surface Starter clutch idle gear shaft Starter clutch gear thrust surface Starter clutch gear inner surface Main axle thrust surfaces Main...

Page 101: ...LUBRICATION POINTS AND LUBRICANT TYPES YP250R 2 70 Crankshaft position sensor stator assembly lead grommet Yamaha bond No 1215 Lubrication point Lubricant ...

Page 102: ... and metal to metal moving parts Rear brake caliper retaining bolt Throttle cable end Throttle grip inner surface and throttle cables Handlebar grip inner surface Rubber adhesive Sidestand pivoting point and metal to metal moving parts Sidestand spring hook metal to metal moving parts Centerstand shaft pivoting point and metal to metal moving parts Centerstand spring hook metal to metal moving par...

Page 103: ...LUBRICATION POINTS AND LUBRICANT TYPES YP250R 2 72 ...

Page 104: ...COOLING SYSTEM DIAGRAMS YP250R 2 73 EAS20420 COOLING SYSTEM DIAGRAMS YP250R A A 4 3 3 2 2 1 3 4 5 2 6 7 ...

Page 105: ...COOLING SYSTEM DIAGRAMS YP250R 2 74 1 Coolant reservoir 2 Coolant reservoir hose 3 Radiator cap 4 Radiator filler hose 5 Radiator 6 Radiator inlet hose 7 Radiator outlet hose ...

Page 106: ...CABLE ROUTING YP250R 2 75 EAS20430 CABLE ROUTING YP250R Battery front view A B C D E F G H 1 1 2 2 3 3 4 5 6 7 8 8 9 9 10 10 12 13 14 15 15 11 11 13 16 17 ...

Page 107: ...y lead to the front of the starter relay C Route the self diagnosis signal lead along the negative battery lead D Route the negative battery lead to the rear of the turn signal hazard relay lead lean angle sensor lead and headlight lead E Route the turn signal hazard relay lead to the rear of the lean angle sensor F Point the end of the plastic locking tie forward and then cut off the excess end o...

Page 108: ...CABLE ROUTING YP250R 2 77 Front fork front view 1 1 2 3 4 5 6 7 1 2 A 1 2 ...

Page 109: ...ont brake hose 3 Rectifier regulator 4 Left front turn signal light coupler 5 Wire harness 6 Horn 7 Right front turn signal light coupler A Point the end of the plastic locking tie forward and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 110: ...CABLE ROUTING YP250R 2 79 Front brake hose right side view 1 1 2 3 4 5 6 7 7 8 8 8 8 8 8 9 10 11 11 11 11 12 13 13 14 15 8 A B ...

Page 111: ...tor 7 Radiator fan motor lead 8 Wire harness 9 Rear brake pipe 10 Horn leads 11 Starter motor lead 12 Headlight relay 13 Rear brake hose 14 Throttle cables 15 Main switch immobilizer unit lead A Position the plastic locking tie above the frame cross member B Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 112: ...CABLE ROUTING YP250R 2 81 Engine right side view A 7 3 2 2 2 1 3 4 5 6 7 8 B ...

Page 113: ...sensor lead 6 O2 sensor 7 Starter motor lead 8 Rear brake hose A Fasten the wire harness starter motor lead crankshaft position sensor stator assembly lead and O2 sensor lead with a plastic locking tie B Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 114: ...CABLE ROUTING YP250R 2 83 Throttle cables left side view A B C I J 1 2 3 3 3 4 5 5 5 6 6 6 6 7 7 8 9 10 11 12 13 14 14 15 16 17 17 D D E F H H G 6 ...

Page 115: ...the rear brake pipe B Route the sidestand switch lead to the inside of the frame C Route the sidestand switch lead to the outside of the frame D Position the connector cover as shown in the illustration E Forward F Fasten the wire harness at the white tape with the holder G Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in H Point ...

Page 116: ...CABLE ROUTING YP250R 2 85 Engine left side view 2 1 3 4 5 6 B A 3 7 ...

Page 117: ...l brake light assembly 5 Safety protector 6 O2 sensor 7 Spark plug cap A Route the left tail brake light assembly lead and right tail brake light assembly lead over the safety protector B Point the end of the plastic locking tie to the left and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 118: ...CABLE ROUTING YP250R 2 87 Handlebar top view A 1 2 3 4 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 ...

Page 119: ...el pump coupler 7 Fuel sender coupler 8 Fuel hose 9 Left handlebar switch lead 10 Rear brake hose 11 ECU engine control unit 12 Positive battery lead 13 Negative battery lead 14 Fuse box 1 15 Fuse box 2 16 Battery 17 Turn signal hazard relay A Point the end of the plastic locking tie to the left and then cut off the excess end of the tie to 0 5 mm 0 0 20 in ...

Page 120: ...CABLE ROUTING YP250R 2 89 Throttle body top view 3 3 1 2 3 A 6 7 8 8 9 13 C B D 11 10 10 11 4 5 4 4 4 4 4 12 12 12 ...

Page 121: ...ensor stator assembly lead 13 O2 sensor lead A Connect the breather hose air filter case to throttle body to the air filter case making sure to turn the white paint marks on the hose upward B Route the seat lock cable to the inside of the frame C Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in D Fasten the fuel injector lead at t...

Page 122: ...CABLE ROUTING YP250R 2 91 Tail brake light top view 2 1 3 4 B A 1 5 6 8 7 ...

Page 123: ...tail brake light assembly coupler 6 Seat lock cable 7 Cylinder head breather hose 8 Intake air temperature sensor coupler A Point the end of the plastic locking tie to the right and then cut off the excess end of the tie to 0 5 mm 0 0 20 in B Route the license plate light lead between the water guard and the license plate light bracket ...

Page 124: ...CABLE ROUTING YP250R 2 93 ...

Page 125: ... V BELT CASE AIR FILTER ELEMENT 3 15 CHECKING THE THROTTLE BODY JOINT 3 16 CHECKING THE FUEL HOSE 3 16 CHECKING THE BREATHER HOSES 3 16 CHECKING THE EXHAUST SYSTEM 3 17 CHECKING THE COOLANT LEVEL 3 17 CHECKING THE COOLING SYSTEM 3 18 CHANGING THE COOLANT 3 18 ENGINE YP250R 3 21 ADJUSTING THE VALVE CLEARANCE 3 21 ADJUSTING THE EXHAUST GAS VOLUME 3 23 ADJUSTING THE THROTTLE CABLE FREE PLAY 3 23 CHEC...

Page 126: ...STEM 3 36 CHECKING AND ADJUSTING THE STEERING HEAD 3 37 CHECKING THE FRONT FORK 3 39 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES 3 39 CHECKING THE TIRES 3 39 CHECKING THE WHEELS 3 41 CHECKING AND LUBRICATING THE CABLES 3 41 LUBRICATING THE LEVERS 3 41 LUBRICATING THE SIDESTAND 3 41 LUBRICATING THE CENTERSTAND 3 42 ELECTRICAL SYSTEM 3 43 CHECKING AND CHARGING THE BATTERY 3 43 CHECKING THE FUSES 3 ...

Page 127: ......

Page 128: ...P125R TIP The annual checks must be performed every year except if a kilometer based maintenance or for the UK a mileage based maintenance is performed instead From 30000 km 17500 mi repeat the maintenance intervals starting from 6000 km 3500 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills NO ITEM CHECK OR MAINTENANCE ...

Page 129: ...operation and shock absorbers for oil leakage 17 Engine oil Change When the oil change indicator flashes 5000 km 3000 mi after the initial 1000 km 600 mi and every 6000 km 3500 mi thereafter Check oil level and vehicle for oil leakage Every 3000 km 1800 mi 18 Engine oil filter el ement Replace 19 Cooling system Check coolant level and vehi cle for coolant leakage Change Every 3 years 20 Final tran...

Page 130: ...eat the maintenance intervals starting from 10000 km 6000 mi Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skills EAU1770C GENERAL MAINTENANCE AND LUBRICATION CHART YP250R TIP The annual checks must be performed every year except if a kilometer based maintenance or for the UK a milage based maintenance is performed instead Fro...

Page 131: ...ration Lubricate 14 Sidestand switch Check operation 15 Front fork Check operation and for oil leakage 16 Shock absorber assemblies Check operation and shock absorbers for oil leakage 17 Engine oil Change When the oil change indicator flashes At 4000 km 2500 mi and every 3000 km 1800 mi thereafter Check oil level and vehicle for oil leakage Every 3000 km 1800 mi 18 Engine oil strain er Clean 19 Co...

Page 132: ... and the V belt air filter element needs to be ser viced more frequently when riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and chang...

Page 133: ...o GENERAL CHASSIS on page 4 1 2 Remove V belt case cover 1 V belt case air duct 2 V belt case air filter element 3 Remove Spark plug cap Spark plug 1 Cylinder head cover 2 4 Remove Timing mark accessing plug 1 5 Measure Valve clearance Out of specification Adjust a Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft b Align the I mark a on the gen...

Page 134: ...specifica tion e Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 7 Install Timing mark accessing plug along with the O ring Cylinder head cover gasket Cylinder head cover Spark plug Spark plug cap 1 1 2 Direction a Valve clearance is increased Direction b Valve cl...

Page 135: ...ting CO press the MODE but ton 8 Check that C1 appears on the LCD of the FI diagnostic tool and then press the MODE button 9 Start the engine NOTICE ECA37P1042 Perform the adjustment after the battery has been sufficiently charged 10 Change the CO adjustment volume by press ing the UP and DOWN buttons TIP The CO adjustment volume and engine idling speed appears on the LCD of the FI diagnostic tool...

Page 136: ... idling speed to change EAS37P1091 CHECKING THE SPARK PLUG 1 Disconnect Spark plug cap 1 2 Remove Spark plug NOTICE ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Re...

Page 137: ...ect Timing light 1 onto the spark plug lead 4 Check Ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check that the stationary pointer a on the generator cover is within the firing range b on the generator rotor Incorrect firing range Check the ignition system TIP The ignition timing is not adjustable 5 Disconnect Timing...

Page 138: ...ING EWA37P1019 To prevent sparking ground the spark plug lead before cranking the engine c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the min imum specification pour a teaspoonful of en gine oil into the spark plug bore and measure again R...

Page 139: ...4 Do not allow foreign materials to enter the crankcase 5 Start the engine warm it up for several min utes and then turn it off 6 Check the engine oil level again TIP Before checking the engine oil level wait a few minutes until the oil has settled 7 Install Dipstick EAS37P1094 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under...

Page 140: ... drain bolt along with the gasket 8 Fill Crankcase with the specified amount of the recom mended engine oil 9 Install Engine oil filler cap 10 Start the engine warm it up for several min utes and then turn it off 11 Check Engine for engine oil leaks 12 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 12 13 Check Engine oil pressure a Slightly loosen the oil check bolt 1 T R ...

Page 141: ...e indicator must be reset as soon as pos sible so that it comes on for the next periodic oil change EAS37P1095 CHANGING THE FINAL TRANSMISSION OIL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure that the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Place a container under the final transmis sion 4 Remove Oil ...

Page 142: ...ed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the throttle body tuning leading to poor engine perfor mance and possible overheating TIP When installing the air filter element into the air filter case cover make sure that the sealing sur faces are aligned to prevent any air leaks EAS37P1097 CLEA...

Page 143: ...n page 4 1 EAS37P1099 CHECKING THE FUEL HOSE 1 Remove Storage box Refer to GENERAL CHASSIS on page 4 1 2 Check Fuel hose 1 Cracks damage Replace the fuel injector assembly Loose connection Connect properly 3 Install Storage box Refer to GENERAL CHASSIS on page 4 1 EAS37P1100 CHECKING THE BREATHER HOSES 1 Remove Storage box Refer to GENERAL CHASSIS on page 4 1 2 Check Cylinder head breather hose 1 ...

Page 144: ...oolant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA37P1048 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However i...

Page 145: ...trest board Bottom cover Storage box Refer to GENERAL CHASSIS on page 4 1 EAS37P1104 CHANGING THE COOLANT 1 Remove Bottom cover Refer to GENERAL CHASSIS on page 4 1 2 Remove Coolant reservoir cap 1 3 Disconnect Coolant reservoir hose 2 4 Drain Coolant from the coolant reservoir 5 Remove Radiator cap 1 WARNING EWA37P1021 A hot radiator is under pressure Therefore do not remove the radiator cap when...

Page 146: ... coolant is swallowed induce vomiting and get immediate medical attention NOTICE ECA37P1049 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into con...

Page 147: ...arm it up for several min utes and then turn it off 15 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 17 TIP Before checking the coolant level wait a few minutes until the coolant has settled 16 Install Bottom cover Refer to GENERAL CHASSIS on page 4 1 a ...

Page 148: ...1 3 Remove Spark plug cap 1 Spark plug Tappet covers 2 Camshaft sprocket cover 3 4 Remove Timing mark accessing plug 1 5 Measure Valve clearance Out of specification Adjust a Turn the primary sheave nut on the left side of the crankshaft counterclockwise to turn the crankshaft b When the piston is at TDC on the compres sion stroke align the I mark a on the cam shaft sprocket with the stationary po...

Page 149: ...valve clearance adjust ment steps until the specified clearance is obtained 7 Install Timing mark accessing plug along with the O ring Camshaft sprocket cover along with the O ring Tappet covers along with the O rings Spark plug Spark plug cap 8 Install V belt case air filter cover 9 Install Storage box Refer to GENERAL CHASSIS on page 4 1 Direction a Valve clearance is increased Direction b Valve...

Page 150: ...ess the MODE button 9 Start the engine NOTICE ECA37P1015 Perform the adjustment after the battery has been sufficiently charged 10 Change the CO adjustment volume by press ing the UP and DOWN buttons TIP The CO adjustment volume and engine idling speed appears on the LCD of the FI diagnostic tool To decrease the CO adjustment volume press the DOWN button To increase the CO adjustment volume press ...

Page 151: ... Spark plug NOTICE ECA13330 Before removing the spark plug blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder 3 Check Spark plug type Incorrect Change 4 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean Spark plug with a spark plug cle...

Page 152: ...ed en gine idling speed b Check that the stationary pointer a on the generator cover is within the firing range b on the generator rotor Incorrect firing range Check the ignition system TIP The ignition timing is not adjustable 5 Disconnect Timing light 6 Install Timing mark accessing plug along with the O ring EAS20710 MEASURING THE COMPRESSION PRESSURE TIP Insufficient compression pressure will ...

Page 153: ...spark plug bore and measure again Refer to the following table 8 Install Spark plug 9 Connect Spark plug cap 10 Install Storage box Refer to GENERAL CHASSIS on page 4 1 EAS20740 CHECKING THE ENGINE OIL LEVEL 1 Stand the vehicle on a level surface TIP Place the vehicle on the centerstand Make sure the vehicle is upright 2 Start the engine warm it up for several min utes and then turn it off 3 Remov...

Page 154: ...arm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler cap 1 Engine oil drain bolt 2 along with the gasket 4 Drain Engine oil completely from the crankcase 5 If the oil strainer is also to be cleaned per form the following procedure a Remove the oil strainer cover 1 and oil strainer 2 b Install a new O ring 3 c Install the...

Page 155: ...check bolt to specification 13 Reset Oil change indicator a Set the main switch to ON b Push the OIL CHANGE button 1 for 15 to 20 seconds c Release the button and the oil change indica tor will go off TIP If the engine oil is changed before the oil change indicator comes on i e before the periodic oil change interval has been reached the oil change indicator must be reset as soon as pos sible so t...

Page 156: ...ir filter element Damage Replace TIP Replace the air filter element every 20000 km of operation The air filter needs more frequent service if you are riding in unusually wet or dusty areas 3 Install Air filter element Air filter case cover NOTICE ECA37P1017 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engi...

Page 157: ...age box Refer to GENERAL CHASSIS on page 4 1 2 Check Throttle body joint 1 Cracks damage Replace 3 Install Storage box Refer to GENERAL CHASSIS on page 4 1 EAS21030 CHECKING THE FUEL HOSE 1 Remove Storage box Refer to GENERAL CHASSIS on page 4 1 2 Check Fuel hose 1 Cracks damage Replace the fuel injector assembly Loose connection Connect properly 3 Install Storage box Refer to GENERAL CHASSIS on p...

Page 158: ...ant level should be between the maximum level mark a and minimum level mark b Below the minimum level mark Add the recommended coolant to the proper level NOTICE ECA37P1019 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if d...

Page 159: ...otrest board Bottom cover Storage box Refer to GENERAL CHASSIS on page 4 1 EAS21130 CHANGING THE COOLANT 1 Remove Bottom cover Refer to GENERAL CHASSIS on page 4 1 2 Remove Coolant reservoir cap 1 3 Disconnect Coolant reservoir hose 2 4 Drain Coolant from the coolant reservoir 5 Remove Radiator cap 1 WARNING EWA37P1004 A hot radiator is under pressure Therefore do not remove the radiator cap when ...

Page 160: ...swallowed induce vomiting and get immediate medical attention NOTICE ECA37P1020 Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with pa...

Page 161: ...arm it up for several min utes and then turn it off 15 Check Coolant level Refer to CHECKING THE COOLANT LEV EL on page 3 31 TIP Before checking the coolant level wait a few minutes until the coolant has settled 16 Install Bottom cover Refer to GENERAL CHASSIS on page 4 1 a ...

Page 162: ...boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately TIP In order to ensure a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all ...

Page 163: ...BRAKE on page 4 17 EAS21290 CHECKING THE REAR BRAKE HOSE 1 Check Brake hose 1 Cracks damage wear Replace 2 Check Brake hose holder 2 Loose connection Connect 3 Hold the vehicle upright and apply the rear brake several times 4 Check Brake hose Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 29 EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING EWA37P1005 Bleed the hydra...

Page 164: ...contact the throttle grip or handlebar grip h Tighten the bleed screw and then release the brake lever i Repeat steps e to h until all of the air bub bles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification k Fill the brake master cylinder reservoir to the proper level with the recommended brake flu id Refer to CHECKING THE BRAKE FLUID LEVEL on page...

Page 165: ... binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 57 e Install the rubber washer f Install the center ring nut g Finger tighten the center ring nut and then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the center ring nut until their slots are aligned TIP Align the slots by turning the center ring...

Page 166: ...e following procedure applies to both of the rear shock absorber assemblies WARNING EWA37P1006 Securely support the vehicle so that there is no danger of it falling over Always adjust both rear shock absorber as semblies evenly Uneven adjustment can result in poor handling and loss of stability Spring preload NOTICE ECA13590 Never go beyond the maximum or minimum adjustment positions 1 Adjust Spri...

Page 167: ...l injury from sudden deflation When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good qual...

Page 168: ...re placed always balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA37P1008 A damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner ca bles as soon as possible 1 Check Outer cable Damage Replace 2 Check Cable operation Rough movement Lubric...

Page 169: ...CHASSIS 3 42 EAS21730 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal to metal moving parts of the centerstand Recommended lubricant Lithium soap based grease ...

Page 170: ...ead light bulb holder NOTICE ECA13690 Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Install Headlight bulb holder with the headlight bulb 7 Install...

Page 171: ...cloth moistened with alcohol or lacquer thinner 7 Attach Headlight bulb holder 8 Connect Headlight coupler 9 Install Headlight bulb cover 10 Install Front cowling assembly Refer to GENERAL CHASSIS on page 4 1 EAS21800 ADJUSTING THE HEADLIGHT BEAM 1 Adjust Headlight beam vertically a Remove the adjusting screw accessing cap b Turn the adjusting screw 1 in direction a or b c Install the adjusting sc...

Page 172: ...ELECTRICAL SYSTEM 3 45 ...

Page 173: ...ASSEMBLING THE FRONT BRAKE CALIPER 4 25 INSTALLING THE FRONT BRAKE CALIPER 4 25 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 26 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 26 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 26 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 27 REAR BRAKE 4 29 INTRODUCTION 4 37 CHECKING THE REAR BRAKE DISC 4 37 REPLACING THE REAR BRAKE PADS YP125R 4 37 REPLACING THE REAR BRA...

Page 174: ...4 53 ASSEMBLING THE FRONT FORK LEGS 4 53 INSTALLING THE FRONT FORK LEGS 4 55 STEERING HEAD 4 57 REMOVING THE LOWER BRACKET 4 59 CHECKING THE STEERING HEAD 4 59 INSTALLING THE STEERING HEAD 4 59 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 61 REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES 4 63 REMOVING THE SWINGARM 4 63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE SWINGARM 4 63 INSTALL...

Page 175: ......

Page 176: ...te light coupler 1 Disconnect 9 Mudguard 1 10 Water guard 1 11 Seat lock cable 1 Disconnect 12 Storage box 1 13 Safety protector 1 For installation reverse the removal proce dure 4 4 3 2 1 5 6 6 7 7 8 9 4 4 12 13 10 11 5 LT LT LT LT LT 23 Nm 2 3 m kgf 17 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 11 Nm 1 1 m...

Page 177: ...on b Install the storage box seat lock cable water guard and mudguard to the vehicle c Pass the license plate light coupler license plate light side through the hole in the safety protector at the location b shown in the illus tration and then connect the coupler d Install the rear panels to the vehicle e Align the holes in the safety protector with the projections on the water guard at the loca t...

Page 178: ...ghtening the mudguard bolts tighten the center bolt a first and then tighten the side bolts b 3 Install Seat TIP Tighten the seat nuts in the proper tightening se quence as shown T R Seat nut 10 Nm 1 0 m kgf 7 2 ft lbf b b a 3 2 1 4 ...

Page 179: ...indshield bracket 1 5 Headlight assembly coupler 1 Disconnect 6 Front cowling assembly 1 7 Headlight assembly 1 For installation reverse the removal proce dure 1 6 6 4 4 7 5 4 2 6 3 LT LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 180: ...ing the headlight assembly 1 Rearview mirror 2 2 Center handlebar cover 1 3 Upper handlebar cover 1 4 Lower handlebar cover 1 5 Storage compartment molding 1 6 Meter assembly coupler 1 Disconnect 7 Meter assembly cover 1 8 Meter assembly 1 For installation reverse the removal proce dure 4 4 4 4 1 2 3 4 5 7 8 6 1 ...

Page 181: ... the seat and storage box Front cowling assembly Refer to Removing the headlight assembly 1 Front turn signal light coupler 2 Disconnect 2 Front upper panel 2 3 Front turn signal light 2 4 Footrest board mat 2 5 Front lower panel 2 6 Radiator cover 1 For installation reverse the removal proce dure 4 3 2 2 3 5 1 1 5 6 ...

Page 182: ...r to Removing the radiator cover 1 Radiator air duct 1 2 Bottom cover 1 3 Auxiliary DC jack coupler OPTION 1 Disconnect 4 Storage compartment 1 5 Footrest board 1 For installation reverse the removal proce dure 4 3 1 2 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 11 Nm 1 1 m kgf 8 0 ft Ibf T R ...

Page 183: ...sensor coupler 1 Disconnect 4 Intake air temperature sensor 1 5 Cylinder head breather hose 1 Disconnect 6 Breather hose air filter case to throttle body 1 Disconnect YP250R only 7 Air filter case joint screw clamp 1 YP125R 8 Air filter case joint screw clamp 1 YP250R 9 Air filter case 1 For installation reverse the removal proce dure LT LT New 2 3 6 1 9 8 7 3 4 5 6 9 Nm 0 9 m kgf 6 5 ft Ibf T R 9...

Page 184: ...ve Q ty Remarks 1 Front wheel axle pinch bolt 1 Loosen 2 Front wheel axle 1 3 Front wheel 1 4 Speed sensor 1 5 Spacer 1 6 Front brake disc 1 For installation reverse the removal proce dure 5 1 2 3 6 4 5 LT LS LS 12 Nm 1 2 m kgf 8 7 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 70 Nm 7 0 m kgf 50 ft Ibf T R ...

Page 185: ...FRONT WHEEL 4 10 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 1 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 1 2 2 3 LS New ...

Page 186: ...revent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller EAS21920 CHECKING THE FRONT WHEEL 1 Check Wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING EWA13460 Do not attempt to straighten a bent wheel ax le 2 Check Tire Front wheel Damage wear Replace Refer to CHECKING THE TIRES on page 3 ...

Page 187: ...e 4 are pressed at the same time and then press the bearing until the inner race makes contact with the spacer 5 EAS21970 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance with the brake disc installed 1 Remove Balancing weight s 2 Find Front wheel s heavy spot TIP Place the fr...

Page 188: ...heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it EAS21990 INSTALLING THE FRONT WHEEL FRONT BRAKE DISC 1 Install Front brake disc TIP In...

Page 189: ...stalling the speed sensor make sure that the projection on the wheel hub does not damage the lip of the speed sensor oil seal Make sure that the slot c in the speed sensor fits over the stopper d on the outer tube 5 Install Wheel axle Wheel axle pinch bolt NOTICE ECA37P1030 Before tightening the wheel axle push down hard on the handlebar several times and check if the front fork rebounds smoothly ...

Page 190: ...L YP250R on page 5 61 Swingarm Refer to REAR SHOCK ABSORBER AS SEMBLIES AND SWINGARM on page 4 61 1 Air filter case mounting bolt 2 2 Rear fender 1 3 Rear wheel 1 4 Washer 1 YP125R 5 Spacer 1 YP250R 6 Rear brake disc 1 For installation reverse the removal proce dure 4 6 3 5 4 2 1 1 LS LT LT LT 9 Nm 0 9 m kgf 6 5 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 9 Nm 0 9 m kgf 6 5 ft Ibf T R ...

Page 191: ...eel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc installed 1 Adjust Rear wheel static balance Refer to ADJUSTING THE FRONT WHEEL STATIC BALANCE on page 4 12 EAS28770 INSTALLING THE REAR WHEEL REAR BRAKE DISC 1 Install Rear brake disc TIP Tighten the brake disc bolts in stages and in a crisscross pattern 2 Check Rear brake disc Re...

Page 192: ...Speed sensor lead guide 1 3 Front brake caliper 1 4 Brake pad pin cap 1 5 Brake pad pin 1 6 Front brake pad 2 7 Brake pad spring 1 8 Brake pad support 1 For installation reverse the removal proce dure 3 7 6 6 8 1 2 1 5 4 40 Nm 4 0 m kgf 29 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R ...

Page 193: ...linder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Front brake lever 1 5 Front brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Front brake hose 1 9 Front brake master cylinder holder 1 10 Front brake master cylinder 1 11 Front brake light switch 1 For installation reverse the removal proce dure S 7 6 8 1 2 3 10 11 9 4 5 New ...

Page 194: ...4 19 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure 1 2 New S S BF ...

Page 195: ...LEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 1 Brake hose union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Front brake caliper bolt 2 5 Speed sensor lead guide 1 6 Front brake caliper 1 For installation reverse the removal proce dure 4 5 4 3 1 2 6 New 40 Nm 4 0 m kgf 29 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R ...

Page 196: ...liper bracket 1 7 Brake caliper piston 2 8 Brake caliper piston dust seal 2 9 Brake caliper piston seal 2 10 Bleed screw 1 11 Brake caliper body 1 For assembly reverse the disassembly pro cedure S S S S BF 6 7 8 9 9 10 3 5 4 8 11 2 1 LT LT New New New New 3 Nm 0 3 m kgf 2 2 ft Ibf T R 6 Nm 0 6 m kgf 4 3 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 23 Nm 2 3 m kgf 17 ft I...

Page 197: ... 1 Remove Front wheel Refer to FRONT WHEEL on page 4 9 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the vehicle on a suitable stand so that the front wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the fro...

Page 198: ...ew brake pad support as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install new brake pad support new brake pad spring and new brake pads 3 Install Brake pad pin Brake pad pin cap Front brake cal...

Page 199: ...e careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seals and brake caliper piston seals EAS22380 CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper a...

Page 200: ...ICE ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Front brake caliper 3 Install Brake pad support Brake pad spring Brake pads Brake pad pin Brake pad pin cap Front brake caliper Speed sensor lead guide Refer to REPLACING THE FRONT BRAKE PADS on page 4 23 4 Fill Brake master cylinder reservoir with ...

Page 201: ...ke master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper washers 2 Front brake hose 3 TIP To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER 1 Check Brake master cylinder Damage scratches wear Replace Brake fluid delivery passages brake...

Page 202: ...he recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not en...

Page 203: ...FRONT BRAKE 4 28 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 a ...

Page 204: ... Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Brake pad clip 1 4 Brake pad pin 1 5 Rear brake pad 2 6 Brake pad spring 1 For installation reverse the removal proce dure S 1 3 4 5 5 6 2 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 205: ...Remarks 1 Rear brake caliper retaining bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 For installation reverse the removal proce dure 2 5 5 4 3 1 4 S S 6 Nm 0 6 m kgf 4 3 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R ...

Page 206: ...inder reservoir diaphragm hold er 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake lever 1 5 Rear brake light switch connector 2 Disconnect 6 Brake hose union bolt 1 7 Copper washer 2 8 Rear brake hose 1 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Rear brake light switch 1 For installation reverse the removal proce dure 5 4 11 3 7 9 8 10 2 1 New 7 6 New S 1...

Page 207: ...4 32 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure BF S S 1 2 New ...

Page 208: ...to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 1 Brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 For installation reverse the removal proce dure 4 5 2 1 3 1 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 28 Nm 2 8 m kgf 20 ft Ibf T R ...

Page 209: ...1 Brake fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 1 Brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 3 5 Rear brake caliper 1 For installation reverse the removal proce dure 1 5 2 3 4 4 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 40 Nm 4 0 m kgf 29 ft Ibf T R ...

Page 210: ...caliper YP125R Order Job Parts to remove Q ty Remarks 1 Brake pad clip 1 2 Brake pad pin 1 3 Rear brake pad 2 4 Brake pad spring 1 5 Bleed screw cap 1 1 For assembly reverse the disassembly pro cedure New 1 2 3 4 5 14 Nm 1 4 m kgf 10 ft Ibf T R S ...

Page 211: ...per bracket 1 3 Rear brake pad 2 4 Brake pad shim 4 5 Brake pad support 2 6 Brake caliper piston 2 7 Brake caliper piston dust seal 2 8 Brake caliper piston seal 2 9 Bleed screw 1 10 Brake caliper body 1 For assembly reverse the disassembly pro cedure 2 10 9 1 4 3 4 8 6 7 5 5 New New BF S S 6 Nm 0 6 m kgf 4 3 ft Ibf T R 27 Nm 2 7 m kgf 19 ft Ibf T R ...

Page 212: ...disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISC on page 4 22 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 22 5 Adjust Brake disc deflection R...

Page 213: ...g Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 EAS22580 REPLACING THE REAR BRAKE PADS YP250R TIP When replacing the brake pads it is not neces sary to disconnect the brake hose or disassem ble the brake caliper 1 Measure Brake pad wear limit a Out of specification Replace the brake pads as a set 2 Install Brake pad supports Brake pad shims onto the brake pads B...

Page 214: ...t or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 EAS22590 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake hose union bolt 1 Copper washers 2 Rear brake hose 3 TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22610 D...

Page 215: ...KING THE REAR BRAKE CALIPER YP250R 1 Check Brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons Brake caliper cylinders 2 Scratches wear Replace the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA37P1014 Whenever a brake caliper...

Page 216: ... holding the brake hose tighten the union bolt within the angle range shown in the illustration 2 Remove Rear brake caliper 3 Install Brake pad spring Brake pads Brake pad pin Brake pad clip Rear brake caliper Refer to REPLACING THE REAR BRAKE PADS YP125R on page 4 37 4 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the desi...

Page 217: ...opper washers 2 Rear brake hose 3 Brake hose union bolt 4 WARNING EWA13530 Proper brake hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING YP250R on page 2 75 NOTICE ECA14170 When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper 2 Remove Rear brake caliper 3 Install Brake pad supports Brake p...

Page 218: ...o the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 35 7 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylinder drain the brake fluid from the entire brake sys tem 1 Remove Brake hose union bolt 1 Copper w...

Page 219: ... right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill Brake master cylinder reservoir with the specified amount of the recom mended brake fluid WARNING EWA13540 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brak...

Page 220: ...level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL on page 3 35 6 Check Brake lever operation Soft or spongy feeling Bleed the brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 36 MIN MIN a ...

Page 221: ...er cylinder 1 5 Right handlebar switch 1 6 Throttle cable 2 Disconnect 7 Throttle grip 1 8 Rear brake light switch connector 2 Disconnect 9 Rear brake master cylinder holder 1 10 Rear brake master cylinder 1 11 Left handlebar switch 1 12 Handlebar grip 1 13 Upper handlebar holder 2 7 5 5 3 13 9 11 6 6 1 14 12 4 2 10 8 1 LS LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m ...

Page 222: ... proce dure Removing the handlebar Order Job Parts to remove Q ty Remarks 7 5 5 3 13 9 11 6 6 1 14 12 4 2 10 8 1 LS LS 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R 26 Nm 2 6 m kgf 19 ft Ibf T R ...

Page 223: ... 2 Install Handlebar Upper handlebar holders NOTICE ECA37P1031 First tighten the front bolt on each handle bar holder then the rear bolt TIP The upper handlebar holders should be installed with the arrow marks a facing forward A 3 Install Handlebar grip a Apply a thin coat of a rubber adhesive to the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off...

Page 224: ...ap based grease Align the projection a on the right handlebar switch with the hole b in the handlebar Be sure to slide the throttle cable rubber cover to its original position 7 Install Front brake master cylinder 1 Front brake master cylinder holder TIP Align the projection a on the brake master cyl inder with the hole b in the handlebar First tighten the front bolt then the rear bolt 8 Adjust Th...

Page 225: ...e 4 1 Front wheel Refer to FRONT WHEEL on page 4 9 1 Front brake caliper 1 2 Front fender 1 3 Cap bolt 1 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 For installation reverse the removal proce dure 3 1 2 4 5 LT LT New LT LT LT LT LT 45 Nm 4 5 m kgf 32 ft Ibf T R 23 Nm 2 3 m kgf 17 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 40 Nm 4...

Page 226: ...ies to both of the front fork legs 1 Fork spring 1 2 Dust seal 1 3 Oil seal clip 1 4 Damper rod bolt 1 5 Copper washer 1 6 Damper rod 1 7 Inner tube 1 8 Oil flow stopper 1 9 Oil seal 1 10 Outer tube 1 For assembly reverse the disassembly pro cedure 1 New New New New 7 2 3 9 10 5 4 8 6 30 Nm 3 0 m kgf 22 ft Ibf T R LT ...

Page 227: ...inch bolts WARNING EWA37P1022 Before loosening the lower bracket pinch bolts support the front fork leg EAS22980 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Drain Fork oil TIP Stroke the inner tube several times while drain ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flat head screwdriver NOTICE ECA14180 Do not scratch the inn...

Page 228: ... FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork legs are equal Uneven oil levels can result in poor han dling and a loss of stability TIP When assembling the front fork leg be sure to replace the following parts Oil seal Dust seal Clip Before assembling the front fork leg make sure all of the components are clea...

Page 229: ...Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install Oil seal clip 1 TIP Adjust the oil seal clip so that it fits into the outer tube s groove 6 Install Dust seal 1 with the fork seal driver weight 2 Damper rod holder 90890 01294 Damping rod holder set YM 01300 T handle 90890 01326 T handle 3 8 drive 60 cm long ...

Page 230: ...inutes until the oil has settled and the air bubbles have dispersed TIP Be sure to bleed the front fork leg of any residual air 10 Measure Front fork leg oil level a from the top of the inner tube with the inner tube fully compressed and without the fork spring Out of specification Correct 11 Install Fork spring EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the...

Page 231: ...nstalling the cap bolt take care not to damage the rectifier regulator with the tools TIP Before installing the cap bolt lubricate its O ring with grease If the cap bolt is difficult to install slightly loos en the lower bracket pinch bolts T R Cap bolt 45 Nm 4 5 m kgf 32 ft lbf New ...

Page 232: ... 1 Speed sensor lead holder bracket 1 2 Steering stem nut 1 3 Lower handlebar holder 1 4 Woodruff key 1 5 Upper ring nut 1 6 Lock washer 1 7 Center ring nut 1 8 Rubber washer 1 9 Lower ring nut 1 10 Lower bracket 1 11 Upper bearing cover 1 12 Upper bearing inner race 1 4 5 6 7 8 9 11 12 13 18 3 2 10 15 16 14 17 1 LS LS 9 Nm 0 9 m kgf 6 5 ft Ibf T R 1st 38 Nm 3 8 m kgf 27 ft lbf 2nd 22 Nm 2 2 m kgf...

Page 233: ... bearing outer race 1 For installation reverse the removal proce dure Removing the lower bracket Order Job Parts to remove Q ty Remarks 4 5 6 7 8 9 11 12 13 18 3 2 10 15 16 14 17 1 LS LS 9 Nm 0 9 m kgf 6 5 ft Ibf T R 1st 38 Nm 3 8 m kgf 27 ft lbf 2nd 22 Nm 2 2 m kgf 16 ft lbf T R 75 Nm 7 5 m kgf 54 ft Ibf T R 120 Nm 12 0 m kgf 85 ft lbf T R ...

Page 234: ...ace 3 Replace Bearings Bearing races a Remove the bearing races from the steering head pipe 1 with a long rod 2 and hammer b Remove the bearing race from the lower bracket 3 with a floor chisel 4 and ham mer c Install new bearing races NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearings and bearing races as a set 4 C...

Page 235: ...ring nut 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 37 3 Install Woodruff key 1 Lower handlebar holder 2 Steering stem nut TIP Align the woodruff key with the groove a in the lower handlebar holder T R Steering stem nut 120 Nm 12 0 m kgf 85 ft lbf 2 a 1 ...

Page 236: ... Rear wheel axle nut 1 2 Brake hose holder 1 3 Rear brake caliper 1 4 Rear shock absorber assembly 2 5 Swingarm 1 6 Spacer 1 7 Collar 1 8 Oil seal 2 9 Bearing 2 For installation reverse the removal proce dure 4 7 3 2 8 5 9 8 6 1 New New 9 LS LS LS 28 Nm 2 8 m kgf 20 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 40...

Page 237: ...e hose holder 1 3 Rear brake caliper 1 4 Rear shock absorber assembly 2 5 Swingarm 1 6 Spacer 1 7 Collar 1 8 Oil seal 1 9 Oil seal 1 10 Circlip 1 11 Bearing 1 For installation reverse the removal proce dure 4 4 2 3 1 6 10 11 9 7 8 5 New New New LT LS LS 18 Nm 1 8 m kgf 13 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 135 Nm 13 5 m kgf 98 ft lbf T R 40 Nm 4 0 m kgf 29 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ib...

Page 238: ...aliper 3 Remove Swingarm EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1 Check Rear shock absorber rod Bends damage Replace the rear shock absorber assembly Rear shock absorber Oil leaks Replace the rear shock absorber assembly Spring Damage wear Replace the rear shock ab sorber assembly Bushings Damage wear Replace Bolts Bends damage wear Replace EAS23370 CHECKING THE SWINGARM 1 Check Swinga...

Page 239: ... nut 135 Nm 13 5 m kgf 98 ft lbf Swingarm mounting bolt upper side 28 Nm 2 8 m kgf 20 ft lbf YP125R 59 Nm 5 9 m kgf 43 ft lbf YP250R Swingarm mounting bolt lower side 28 Nm 2 8 m kgf 20 ft lbf YP125R 59 Nm 5 9 m kgf 43 ft lbf YP250R A YP125R B YP250R 3 1 2 4 A 3 2 1 4 B ...

Page 240: ...REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4 65 ...

Page 241: ...VE SEATS 5 21 CHECKING THE VALVE SPRINGS 5 22 INSTALLING THE VALVES 5 23 CYLINDER AND PISTON YP125R 5 25 REMOVING THE PISTON 5 26 CHECKING THE CYLINDER AND PISTON 5 26 CHECKING THE PISTON RINGS 5 27 CHECKING THE PISTON PIN 5 28 CHECKING THE TIMING CHAIN GUIDE 5 28 INSTALLING THE PISTON AND CYLINDER 5 28 V BELT AUTOMATIC TRANSMISSION YP125R 5 30 REMOVING THE PRIMARY SHEAVE 5 33 REMOVING THE SECONDA...

Page 242: ...SHAFT ASSEMBLY 5 56 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 56 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 56 CHECKING THE CRANKCASE 5 57 CHECKING THE BEARING AND OIL SEAL 5 57 CHECKING THE OIL PUMP DRIVE GEAR 5 57 CHECKING THE OIL STRAINERS 5 58 INSTALLING THE CRANKSHAFT 5 58 ASSEMBLING THE CRANKCASE 5 59 ENGINE REMOVAL YP250R 5 61 INSTALLING THE ENGINE 5 65 CYLINDER HEAD YP250R 5 67 ...

Page 243: ...TCH SHOES 5 94 CHECKING THE V BELT 5 94 CHECKING THE PRIMARY SHEAVE 5 95 CHECKING THE PRIMARY SHEAVE WEIGHTS 5 95 CHECKING THE PRIMARY SHEAVE SLIDERS 5 95 CHECKING THE SECONDARY SHEAVE 5 95 ASSEMBLING THE PRIMARY SHEAVE 5 95 ASSEMBLING THE SECONDARY SHEAVE 5 96 INSTALLING THE V BELT 5 97 STARTER CLUTCH AND GENERATOR YP250R 5 99 REMOVING THE GENERATOR 5 101 REMOVING THE STARTER CLUTCH 5 101 CHECKIN...

Page 244: ...ASSEMBLY 5 117 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 118 CHECKING THE CRANKSHAFT AND CONNECTING ROD 5 118 CHECKING THE CRANKCASE 5 119 CHECKING THE BEARING AND OIL SEAL 5 119 CHECKING THE OIL STRAINERS 5 119 INSTALLING THE CRANKSHAFT 5 119 ASSEMBLING THE CRANKCASE 5 120 ...

Page 245: ......

Page 246: ...ts to remove Q ty Remarks 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler 1 4 Gasket 1 5 Exhaust pipe 1 6 Gasket 1 For installation reverse the removal proce dure 1 2 3 4 5 6 New New 14 Nm 1 4 m kgf 10 ft Ibf T R 45 Nm 4 5 m kgf 32 ft Ibf T R 53 Nm 5 3 m kgf 38 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R ...

Page 247: ... duct joint Refer to V BELT AUTOMATIC TRANSMIS SION YP125R on page 5 30 Fuel injector assembly Throttle body Intake manifold Refer to THROTTLE BODY on page 7 5 1 Spark plug cap 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Crankshaft position sensor stator assembly coupler 2 Disconnect 4 Radiator inlet hose 1 Disconnect 5 Radiator outlet hose 1 Disconnect 6 Cylinder head breathe...

Page 248: ...MOVAL YP125R 5 3 8 Ground lead 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 3 5 1 2 4 8 7 6 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 249: ...sorber 2 3 Engine mounting nut washer bolt 1 1 1 4 Spacer 1 5 Engine bracket rod nut washer bolt 2 2 2 6 Engine bracket rod 2 7 Engine 1 8 Engine bracket nut bolt 2 2 9 Engine bracket 1 For installation reverse the removal proce dure 8 9 5 8 5 2 1 5 7 4 3 5 8 6 6 3 18 Nm 1 8 m kgf 13 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 64 Nm 6 4 m kgf 46 ft Ibf T R 64 Nm 6 4 m kg...

Page 250: ...ar shock absorber assembly upper nuts Rear shock absorber assembly lower bolts 4 Install Gasket Exhaust pipe Exhaust pipe nuts temporarily tighten 5 Install Muffler Muffler mounting bolts temporarily tighten TIP Install the muffler mounting bolts in the proper in stalling sequence as shown 6 Tighten Muffler mounting bolts T R Engine bracket rod nut 64 Nm 6 4 m kgf 46 ft lbf Engine mounting nut 43 ...

Page 251: ...ing bolts in the proper tightening sequence as shown 7 Tighten Exhaust pipe nuts 8 Tighten Muffler joint bolt O2 sensor T R Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf T R Muffler joint bolt 14 Nm 1 4 m kgf 10 ft lbf O2 sensor 45 Nm 4 5 m kgf 32 ft lbf 1 2 3 ...

Page 252: ... case air duct 1 6 V belt case air filter element 1 7 Cylinder head cover 1 8 Cylinder head cover gasket 1 9 Timing chain tensioner 1 10 Timing chain tensioner gasket 1 11 Camshaft sprocket 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ib...

Page 253: ...marks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 13 Nm 1 3 m kgf 9 4 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 30 Nm 3 0 m kgf 22 ft Ibf T R 7 8 13 14 14 6 5 2 3 1 12 11 9 10 4 4 New New New New New New New New LS 4 4 E LS New ...

Page 254: ...shaft sprocket bolt 1 TIP While holding the primary sheave nut with a wrench remove the camshaft sprocket bolt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sprocket 2 TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 3 4 Remove Cylinder head TIP Loosen the bolts and nuts in the proper se quence as shown Loosen each bolt...

Page 255: ...surface the cylinder head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS37P1004 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket timing chain and crank shaft as a set EAS37P1005 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace a Rem...

Page 256: ...on the generator rotor with the stationary pointer b on the genera tor cover c Install the timing chain 1 onto the camshaft sprocket 2 then the camshaft sprocket onto the camshaft and then finger tighten the camshaft sprocket bolt TIP Fit the projections c on the camshaft into the holes d in the camshaft sprocket and fit the pin e on the decompression cam into the slot f in the decompression lever...

Page 257: ... gasket TIP Apply sealant to the threads of the timing chain tensioner bolts d Turn the timing chain tensioner rod counter clockwise with a thin screwdriver 1 make sure it releases and then install the timing chain tensioner plug 4 Turn Crankshaft turn the primary sheave nut on the left side of the crankshaft several turns counterclock wise 5 Check I mark a Make sure the I mark a on the generator ...

Page 258: ...hten the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 7 Measure Valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE on page 3 6 T R Camshaft sprocket bolt 30 Nm 3 0 m kgf 22 ft lbf d c ...

Page 259: ... YP125R on page 5 7 1 Locknut 4 2 Adjusting screw 4 3 Decompression cam 1 4 Camshaft retainer 1 5 Camshaft 1 6 Rocker arm shaft 2 7 Intake rocker arm 1 8 Exhaust rocker arm 1 For installation reverse the removal proce dure 1 2 1 2 7 3 4 5 6 6 2 1 2 1 8 M M M M E E M LT LT 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 260: ...aft sprocket and the decompression cam installed to the camshaft b Check that the decompression lever 1 moves smoothly c Without operating the decompression lever check that the decompression cam 2 projects from the camshaft exhaust cam as shown in the illustration A d Move the decompression lever in the direc tion of the arrow shown and check that the decompression cam does not project from the c...

Page 261: ...tion Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defective part s 2 A 2 B 1 Rocker arm inside diameter 9 985 10 000 mm 0 3931 0 3937 in Limit 10 015 mm 0 394...

Page 262: ...e illustration Make sure the rocker arm shafts intake and exhaust are completely pushed into the cylin der head 4 Install Camshaft 1 TIP Make sure that the camshaft projections a and hole b are positioned as shown in the illustra tion 5 Install Camshaft retainer Recommended lubricant Camshaft Molybdenum disulfide grease Camshaft bearing Engine oil Recommended lubricant Molybdenum disulfide oil a 1...

Page 263: ...DER HEAD YP125R on page 5 7 Rocker arms Camshaft Refer to CAMSHAFT YP125R on page 5 14 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Lower spring seat 4 8 Valve guide 4 For installation reverse the removal proce dure M 6 6 6 6 1 1 2 2 3 3 7 7 8 5 8 5 8 4 8 4 1 2 3 7 1 2 3 7 New New New New New New New New M M M M M M M ...

Page 264: ... cotters 1 TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS37P1015 CHECKING THE VALVES AND VALVE GUIDES The fo...

Page 265: ...roper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve guide position Intake 17 0 17 4 mm 0 670 0 685 in Exhaust 14 0 14 4 mm 0 551 0 567 in a Val...

Page 266: ...e applies to all of the valves and valve seats 1 Eliminate Carbon deposits from the valve face and valve seat 2 Check Valve seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the...

Page 267: ...ts lightly tap the valve seat while rotating the valve back and forth be tween your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the val...

Page 268: ...icant 3 Install Lower spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Upper spring seat 5 into the cylinder head TIP Make sure each valve is installed in its original place Install the valve springs with the larger pitch a facing up Installed compression spring force intake 140 162 N 14 28 16 52 kgf 31 47 36 42 lbf Installed compression spring force exhaust 140 162 N 14 28 16 52 kgf 31 47 3...

Page 269: ...spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 YM 04019 Valve spring compressor attach ment 90890 04108 Valve spring compressor adapt er 22 mm YM 04108 2 1 ...

Page 270: ...ks Cylinder head Refer to CYLINDER HEAD YP125R on page 5 7 1 Timing chain guide exhaust side 1 2 Cylinder 1 3 Cylinder gasket 1 4 Dowel pin 2 5 Clip 2 6 Piston pin 1 7 Piston 1 8 Top ring 1 9 2nd ring 1 10 Oil ring 1 For installation reverse the removal proce dure 2 4 4 3 5 7 6 5 8 9 10 1 New New New New E E E 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 271: ...ing open the end gap with your fingers and lift the other side of the ring over the piston crown EAS37P1021 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge TIP Measure cylinder bore C by t...

Page 272: ...on Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown b 5 mm 0 20 in from the bottom edge of the piston Piston Diameter D 51 962 51 985 mm 2 0457 2 0466 in Piston to cylind...

Page 273: ...NG CHAIN GUIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS37P1024 INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 TIP Be sure to install the piston rings so that the manufacturer marks or numbers face up Piston ring Top ring End gap installed 0 10 0 25 mm 0 0039 0 0098 in Limit 0 50 mm 0 0197 in ...

Page 274: ...rankcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder 1 TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil New 1 2 3 a New a Top rin...

Page 275: ...RAL CHASSIS on page 4 1 1 V belt case cover 1 2 V belt case air duct joint 1 3 V belt case air duct 1 4 V belt case air filter element 1 5 V belt case 1 6 V belt case gasket 1 1 7 V belt case gasket 2 1 8 Dowel pin 1 9 Bearing 1 For installation reverse the removal proce dure New New 6 5 7 New 9 2 3 3 1 8 4 E 8 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf ...

Page 276: ... 1 1 2 Primary fixed sheave 1 3 Washer 1 4 Secondary sheave nut 1 5 Spacer 1 6 Clutch housing 1 7 Secondary sheave assembly 1 8 V belt 1 9 Primary sliding sheave 1 10 Oil seal 2 11 Spacer 1 12 Cam 1 13 Primary sheave weight 6 14 Slider 3 For installation reverse the removal proce dure 8 7 6 11 3 2 1 5 4 14 12 13 9 10 10 New New New 55 Nm 5 5 m kgf 40 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R ...

Page 277: ...1 2 Clutch carrier 1 3 Clip 3 4 Clutch carrier plate 1 5 Clutch shoe spring 3 6 Compression spring 1 7 Spring seat 1 8 Guide pin 3 9 Secondary sliding sheave 1 10 O ring 2 11 Oil seal 2 12 Oil seal 1 13 Secondary fixed sheave 1 For assembly reverse the disassembly pro cedure 12 7 6 3 4 5 2 1 13 8 8 8 9 11 11 New New New New New New 10 90 Nm 9 0 m kgf 65 ft Ibf T R ...

Page 278: ...housing 2 TIP While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut 2 Loosen Clutch carrier nut 1 NOTICE ECA13860 Do not remove the clutch carrier nut at this stage TIP While holding the clutch carrier with the sheave holder 2 loosen the clutch carrier nut one full turn with the locknut wrench 3 3 Remove Secondary sheave assembly 1 V belt 2 TIP Remove the V belt...

Page 279: ...o all of the clutch shoes 1 Check Clutch shoe Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per TIP After sanding the glazed areas clean the clutch with a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS37P1030 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Cle...

Page 280: ...eck Primary sheave slider Cracks damage wear Replace EAS37P1034 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sliding sheaves as a set 2 Check Torque cam groove 1 Damage wear Replace the secondary fixed and sliding sheaves as a set 3 Check Guide pin 2 Damage wear Replace the secondary fixed and sliding shea...

Page 281: ...Secondary sliding sheave inner surface 2 Oil seals Bearing with the recommended lubricant 2 Install Oil seal Secondary sliding sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 3 Install Guide pins 1 4 Lubricate Guide pin grooves 2 O rings 3 with the recommended lubricant 5 Install Spring seat Compression spring Clutch carrier 1 Clutch ca...

Page 282: ...mary sheave side 2 Tighten Clutch carrier nut 1 TIP While holding the clutch carrier with the sheave holder 2 tighten the clutch carrier nut with the locknut wrench 3 3 Install Clutch housing 1 Spacer Secondary sheave nut 2 TIP While holding the clutch housing with the sheave holder 3 tighten the secondary sheave nut Clutch spring holder 90890 01337 Clutch spring holder arm 90890 01464 2 a 1 2 T R...

Page 283: ...OTICE ECA37P1014 Do not allow grease to contact the primary sheave assembly 5 Tighten Primary sheave nut 1 TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primary sheave nut 6 Install V belt case TIP Make sure that the V belt case gasket lip fits properly around the V belt case Tighten the V belt case bolts in stages and in a crisscross pattern T R Primary shea...

Page 284: ...er to ENGINE REMOVAL YP125R on page 5 1 1 Crankshaft position sensor coupler Stator as sembly coupler 1 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Crankshaft position sensor 1 6 Stator coil 1 7 Oil seal 1 For installation reverse the removal proce dure 1 6 5 7 4 3 4 2 9 3 1 New New New LT LT LT LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 ...

Page 285: ...emarks 1 Circlip 1 2 Washer 1 3 Starter clutch idle gear shaft 1 4 Starter clutch idle gear 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Starter clutch 1 For installation reverse the removal proce dure 4 6 8 7 5 3 3 2 1 New E E E M E LT LT E 13 Nm 1 3 m kgf 9 4 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R ...

Page 286: ...haft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator rotor EAS37P1040 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow the sheave holder to touch th...

Page 287: ... generator rotor 2 with the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS37P1043 INSTALLING THE GENERATOR 1 Install Starter clutch gear Woodruff key Generator rotor Washer Generator rotor nut TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure t...

Page 288: ...all Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Sheave holder 90890 01701 Primary clutch holder YS 01880 A Yamaha bond No 1215 90890 85505 Three Bond No 1215 Oil seal installed depth 4 5 5 4 mm 0 18 0 21 in a Oil seal installed depth 1 2 3 New a 1 New T R Generator cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf ...

Page 289: ...tarter motor Order Job Parts to remove Q ty Remarks Storage box Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal proce dure 2 1 3 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 290: ...motor Order Job Parts to remove Q ty Remarks 1 O ring 1 2 Starter motor yoke 1 3 O ring 1 4 Armature assembly 1 5 Shim 6 Brush 2 7 Spring 2 8 Front bracket brush holder set 1 For assembly reverse the disassembly pro cedure 1 7 3 5 4 2 8 6 7 6 New LS New New ...

Page 291: ...n Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 16 6 mm 0 65 in Mica undercut depth 1 ...

Page 292: ...ELECTRIC STARTER YP125R 5 47 7 Check Gear teeth Damage wear Replace the gear 8 Check Bearing Oil seal Bushing Damage wear Replace the defective part s ...

Page 293: ... CLUTCH AND GENER ATOR YP125R on page 5 39 1 Oil pump plate 1 2 Oil pump assembly 1 3 Oil pump housing cover 1 4 Pin 1 5 Oil pump driven gear 1 6 Oil pump inner rotor 1 7 Oil pump outer rotor 1 8 Oil pump housing 1 For installation reverse the removal proce dure 2 1 3 6 7 8 4 5 M LT E 4 Nm 0 4 m kgf 2 9 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 294: ...t s EAS37P1048 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor 2 Lubricate Oil pump shaft with the recommended lubricant 3 Install Oil pump driven gear Oil pump housing 1 Oil pump outer rotor 2 Oil pump inner rotor 3 Pin 4 Oil pump housing cover 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 15 mm 0 0059 in Limit 0 23 mm 0 0091 in Ou...

Page 295: ... groove a in the inner rotor 4 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 49 EAS37P1049 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA37P1006 After tightening the screws make sure the oil pump turns smoothly T R Oil pump assembly screw 4 Nm 0 4 m kgf 2 9 ft lbf 1 3 4 2 a ...

Page 296: ...MISSION OIL on page 3 14 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION YP125R on page 5 30 1 Transmission case cover 1 2 Gasket 1 3 Dowel pin 2 4 Primary drive gear 1 5 Washer 1 6 Conical spring washer 1 7 1st wheel gear 1 8 Conical spring washer 1 9 Main axle primary driven gear 1 10 Washer 1 11 7 10 9 6 5 3 3 4 6 5 2 1 6 8 8 11 7 9 E E E E E E E New New New New LS A B A B 16 ...

Page 297: ... axle 1 For installation reverse the removal proce dure Removing the transmission Order Job Parts to remove Q ty Remarks 11 7 10 9 6 5 3 3 4 6 5 2 1 6 8 8 11 7 9 E E E E E E E New New New New LS A B A B 16 Nm 1 6 m kgf 11 ft Ibf T R LS ...

Page 298: ... discoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 2 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 3 Check Transmission gear movement Rough movement Replace the defective part s EAS37P1053 INSTALLING THE TRANSMISSION 1 Instal...

Page 299: ...on page 5 30 Oil pump assembly Refer to OIL PUMP YP125R on page 5 48 Transmission Refer to TRANSMISSION YP125R on page 5 51 1 Oil filter element cover 1 2 Oil filter element 1 3 Oil strainer cover 1 4 Spring 1 5 Oil strainer 1 6 Timing chain guide retaining bolt 1 5 4 3 11 9 9 13 12 14 10 7 2 1 15 6 8 3 3 5 New New New New New New New LS LS LS LS E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kg...

Page 300: ...5 Oil seal 1 For installation reverse the removal proce dure Removing the crankshaft Order Job Parts to remove Q ty Remarks 5 4 3 11 9 9 13 12 14 10 7 2 1 15 6 8 3 3 5 New New New New New New New LS LS LS LS E E E 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R ...

Page 301: ...ankshaft assembly with the crankcase separating tool 2 and M6 bolts 3 Make sure that the crankcase separating tool is centered over the crankshaft assembly NOTICE ECA37P1008 To protect the end of the crankshaft place an appropriate sized socket 4 between the crankcase separating tool bolt and the crankshaft Do not tap on the crankshaft EAS37P1057 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 ...

Page 302: ...CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passages Obstruction Blow out with compressed air EAS37P1060 CHECKING THE BEARING AND OIL SEAL 1 Check Bearing Clean and lubricate the bearings and then rotate the inner race with your finger Ro...

Page 303: ...the oil seal lips with lithium soap based grease and each bearing with engine oil TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing 5 Install Oil pump drive gear 1 TIP Install the oil pump drive gear with the crankshaft i...

Page 304: ...ankcase bolts TIP Tighten the crankcase bolts in stages and in a crisscross pattern M6 110 mm 4 33 in bolts 1 M6 80 mm 3 15 in bolts 2 M6 70 mm 2 76 in bolts 3 5 Install Oil filter element cover 1 TIP Be sure to face the mark a on the oil filter element cover in the direction shown in the illus tration Crankshaft installer pot 90890 01274 Installing pot YU 90058 Crankshaft installer bolt 90890 012...

Page 305: ...CRANKSHAFT YP125R 5 60 a 1 ...

Page 306: ...ts to remove Q ty Remarks 1 O2 sensor coupler 1 Disconnect 2 O2 sensor 1 3 Muffler 1 4 Gasket 1 5 Exhaust pipe 1 6 Gasket 1 For installation reverse the removal proce dure 3 4 5 2 1 6 New New 14 Nm 1 4 m kgf 10 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 65 Nm 6 5 m kgf 47 ft Ibf T R 45 Nm 4 5 m kgf 32 ft Ibf T R ...

Page 307: ... GENERAL CHASSIS on page 4 1 Fuel injector assembly Throttle body Intake manifold Refer to THROTTLE BODY on page 7 5 1 Spark plug cap 1 Disconnect 2 Coolant temperature sensor coupler 1 Disconnect 3 Crankshaft position sensor stator assembly coupler 2 Disconnect 4 Radiator inlet hose 1 Disconnect 5 Radiator outlet hose 1 Disconnect 6 Cylinder head breather hose 1 7 Starter motor lead 1 Disconnect ...

Page 308: ...MOVAL YP250R 5 63 8 Ground lead 1 Disconnect For installation reverse the removal proce dure Disconnecting the leads and hoses Order Job Parts to remove Q ty Remarks 8 7 3 2 1 4 6 5 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 309: ...sorber 2 3 Engine mounting nut washer bolt 1 1 1 4 Spacer 1 5 Engine bracket rod nut washer bolt 2 2 2 6 Engine bracket rod 2 7 Engine 1 8 Engine bracket nut bolt 2 2 9 Engine bracket 1 For installation reverse the removal proce dure 8 9 5 8 5 2 1 5 7 4 3 5 8 6 6 3 18 Nm 1 8 m kgf 13 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R 59 Nm 5 9 m kgf 43 ft Ibf T R 64 Nm 6 4 m kgf 46 ft Ibf T R 64 Nm 6 4 m kg...

Page 310: ...ar shock absorber assembly upper nuts Rear shock absorber assembly lower bolts 4 Install Gasket Exhaust pipe Exhaust pipe nuts temporarily tighten 5 Install Muffler Muffler mounting bolts temporarily tighten TIP Install the muffler mounting bolts in the proper in stalling sequence as shown 6 Tighten Muffler mounting bolts T R Engine bracket rod nut 64 Nm 6 4 m kgf 46 ft lbf Engine mounting nut 43 ...

Page 311: ...ing bolts in the proper tightening sequence as shown 7 Tighten Exhaust pipe nuts 8 Tighten Muffler joint bolt O2 sensor T R Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf T R Muffler joint bolt 14 Nm 1 4 m kgf 10 ft lbf O2 sensor 45 Nm 4 5 m kgf 32 ft lbf 2 3 1 ...

Page 312: ...cket cover 1 7 Tappet cover 2 8 Timing chain tensioner 1 9 Timing chain tensioner gasket 1 10 Camshaft sprocket plate 1 11 Camshaft sprocket 1 12 Dowel pin 1 13 Cylinder head 1 3 4 1 4 7 2 8 14 15 9 12 11 10 13 7 5 6 E New New New New New New New LS LS New New LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 ...

Page 313: ... 4 7 2 8 14 15 9 12 11 10 13 7 5 6 E New New New New New New New LS LS New New LS LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 8 Nm 0 8 m kgf 5 8 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 18 Nm 1 8 m kgf 13 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 314: ...ave nut with a wrench remove the camshaft sprocket bolt 3 Remove Timing chain tensioner along with the gasket Camshaft sprocket bolt 1 Camshaft sprocket plate 2 Camshaft sprocket TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 3 4 Remove Cylinder head TIP Loosen the bolts and nuts in the proper se quence as shown Loosen each bolt and nut 1 2 of a turn at a tim...

Page 315: ...head using a figure eight sanding pattern TIP To ensure an even surface rotate the cylinder head several times EAS23870 CHECKING THE CAMSHAFT SPROCKET 1 Check Camshaft sprocket More than 1 4 tooth wear a Replace the camshaft sprocket timing chain and crank shaft as a set EAS24190 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Replace 2 Check One way cam operation ...

Page 316: ...camshaft sprocket and then install the camshaft sprocket onto the camshaft TIP When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side Align the dowel pin 1 on the camshaft with the slot in the camshaft sprocket NOTICE ECA37P1009 Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing e Install the cam...

Page 317: ...amshaft sprocket is aligned with the stationary pointer d on the cylinder head Out of alignment Correct Refer to the installation steps above 6 Tighten Camshaft sprocket bolt NOTICE ECA37P1010 Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil ity of the bolt coming loose and damaging the engine 7 Measure Valve clearance Out of specification Adjust Refer to...

Page 318: ...50R on page 5 67 1 Locknut 2 Loosen 2 Adjusting screw 2 Loosen 3 Lock plate 1 4 Camshaft retainer 1 5 Intake rocker arm shaft 1 6 Exhaust rocker arm shaft 1 7 Rocker arm 2 8 Camshaft 1 For installation reverse the removal proce dure 1 2 7 1 2 7 8 6 5 4 3 New New LS 8 Nm 0 8 m kgf 5 8 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R E E M M M ...

Page 319: ...ECKING THE CAMSHAFT 1 Check Camshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 YU 01083 3 Camshaft lobe dimensions Intake A 37 051 37 151 mm 1 4587 1 4626 in Limit 36 950 mm 1 4547 in Intake B 30 074 30 174 mm...

Page 320: ... shaft clearance TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from the rocker arm inside diameter Out of specification Replace the defective part s EAS24040 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1 Lubricate Camshaft 2 Lubricate Rocker arms Rocker arm shafts Rocker arm inside diameter 12 000 12 018 mm 0 4724 0 4731 in Limit 12 030 mm 0 4736 in Rocker arm shaft...

Page 321: ... Intake rocker arm shaft 1 TIP Insert a guide stud 8 mm 2 into the stud bolt hole in the cylinder head and install the intake rocker arm shaft as shown NOTICE ECA13780 Make sure the threaded part of the rocker arm shaft faces out 5 Install Camshaft retainer 1 Lock plate 2 TIP Bend the lock plate tabs along a flat side of the bolts 3 T R Camshaft retainer bolt 8 Nm 0 8 m kgf 5 8 ft lbf New ...

Page 322: ... HEAD YP250R on page 5 67 Rocker arms Camshaft Refer to CAMSHAFT YP250R on page 5 73 1 Valve cotter 4 2 Upper spring seat 2 3 Outer valve spring 2 4 Inner valve spring 2 5 Intake valve 1 6 Exhaust valve 1 7 Valve stem seal 2 8 Lower spring seat 2 9 Valve guide 2 10 Clip 2 For installation reverse the removal proce dure 6 5 9 8 7 3 4 2 1 9 8 10 7 3 4 2 1 New New New New New 10 New M M M ...

Page 323: ...TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 3 Remove Upper spring seat 1 Outer valve spring 2 Inner valve spring 3 Valve 4 Valve stem seal 5 Lower spring seat 6 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE...

Page 324: ... the proper valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in ...

Page 325: ...e seat Pitting wear Replace the cylinder head 3 Measure Valve seat width a Out of specification Replace the cylinder head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted o...

Page 326: ... face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width again If the valve seat ...

Page 327: ...76 88 N 7 75 8 97 kgf 17 08 19 78 lbf Installed compression spring force exhaust 76 88 N 7 75 8 97 kgf 17 08 19 78 lbf Installed length intake 30 10 mm 1 19 in Installed length exhaust 30 10 mm 1 19 in Outer spring Installed compression spring force intake 115 133 N 11 73 13 56 kgf 25 85 29 90 lbf Installed compression spring force exhaust 115 133 N 11 73 13 56 kgf 25 85 29 90 lbf Installed length...

Page 328: ...stall Valve cotters 1 TIP Install the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch New Valve spring compressor 90890 04019 ...

Page 329: ...r to CYLINDER HEAD YP250R on page 5 67 1 Water pump outlet pipe 1 2 Timing chain guide exhaust side 1 3 Cylinder 1 4 Cylinder gasket 1 5 Dowel pin 2 6 Clip 2 7 Piston pin 1 8 Piston 1 9 Top ring 1 10 2nd ring 1 11 Oil ring 1 For installation reverse the removal proce dure E New New New New New E E LS LS 3 5 4 6 8 7 6 2 11 10 9 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 330: ...n ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24390 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge TIP Measure cylinder bore C by ...

Page 331: ...n Replace the piston and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Level the piston ring into the cylinder with the piston crown b 5 mm 0 20 in from the bottom edge of the piston Piston Diameter D 68 965 68 980 mm 2 7152 2 7157 in Piston to cylinde...

Page 332: ...NG CHAIN GUIDE 1 Check Timing chain guide exhaust side Damage wear Replace EAS24450 INSTALLING THE PISTON AND CYLINDER 1 Install Top ring 1 2nd ring 2 Upper oil ring rail 3 Oil ring expander 4 Lower oil ring rail 5 TIP Be sure to install the piston rings so that the manufacturer marks or numbers face up Piston ring Top ring End gap installed 0 15 0 30 mm 0 0059 0 0118 in Limit 0 55 mm 0 0217 in 2n...

Page 333: ...to the crankcase 3 Lubricate Piston Piston rings Cylinder with the recommended lubricant 4 Offset Piston ring end gaps 5 Install Dowel pins Cylinder gasket Cylinder TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide intake side through the timing chain cavity Recommended lubricant Engine oil New a Top ring b Up...

Page 334: ...r filter case Refer to GENERAL CHASSIS on page 4 1 1 V belt case air filter cover 1 2 V belt case air filter element 1 3 V belt case cover 1 4 V belt case 1 5 V belt case gasket 1 6 Dowel pin 2 For installation reverse the removal proce dure 3 4 11 5 6 6 1 New 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New New 2 ...

Page 335: ...ary sheave bracket 1 4 Secondary sheave nut 1 5 Spacer 1 6 Clutch housing 1 7 Secondary sheave assembly 1 8 V belt 1 9 Primary sliding sheave 1 10 Spacer 1 11 Primary sheave cap 1 12 Cam 1 13 Weight 8 14 Slider 4 LS LS LS LS LT LT E 4 11 14 15 12 13 9 New New New 10 2 1 3 8 7 4 4 6 5 22 Nm 2 2 m kgf 16 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf...

Page 336: ...e removal proce dure Yamaha grease G 90793 40016 Removing the V belt primary sheave and secondary sheave Order Job Parts to remove Q ty Remarks LS LS LS LS LT LT E 4 11 14 15 12 13 9 New New New 10 2 1 3 8 7 4 4 6 5 22 Nm 2 2 m kgf 16 ft Ibf T R 60 Nm 6 0 m kgf 43 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf T R ...

Page 337: ...rrier nut 1 2 Clutch carrier 1 3 Clip 3 4 Clutch carrier plate 1 5 Clutch shoe spring 3 6 Compression spring 1 7 Spring seat 1 8 Guide pin 4 9 Secondary sliding sheave 1 10 O ring 2 11 Oil seal 2 12 Secondary fixed sheave 1 For assembly reverse the disassembly pro cedure New LS LS 5 New 3 4 New 10 New 11 New 11 9 8 12 6 7 1 2 90 Nm 9 0 m kgf 65 ft Ibf T R ...

Page 338: ...using 2 TIP While holding the clutch housing with the sheave holder 3 loosen the secondary sheave nut 2 Loosen Clutch carrier nut 1 NOTICE ECA13860 Do not remove the clutch carrier nut at this stage TIP While holding the clutch carrier with the sheave holder 2 loosen the clutch carrier nut one full turn with the locknut wrench 3 3 Remove Secondary sheave assembly 1 V belt 2 TIP Remove the V belt a...

Page 339: ...all of the clutch shoes 1 Check Clutch shoe Damage wear Replace the clutch shoes and springs as a set Glazed areas Sand with coarse sandpa per TIP After sanding the glazed areas clean the clutch with a cloth 2 Measure Clutch shoe thickness a Out of specification Replace the clutch shoes and springs as a set EAS24670 CHECKING THE V BELT 1 Check V belt 1 Cracks damage wear Replace Grease oil Clean t...

Page 340: ...ck Primary sheave slider Cracks damage wear Replace EAS24710 CHECKING THE SECONDARY SHEAVE 1 Check Secondary fixed sheave Secondary sliding sheave Cracks damage wear Replace the sec ondary fixed and sliding sheaves as a set 2 Check Torque cam groove 1 Damage wear Replace the secondary fixed and sliding sheaves as a set 3 Check Guide pin 2 Damage wear Replace the secondary fixed and sliding sheaves...

Page 341: ...g sheave 1 TIP Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3 3 Install Guide pins 1 4 Lubricate Guide pin grooves 2 O rings 3 with the recommended lubricant 5 Install Spring seat Compression spring Spacer Clutch carrier 1 Clutch carrier nut 2 TIP While compressing the compression spring with the clutch spring holder 3 and clutch spring holder arm ...

Page 342: ...t 1 TIP While holding the clutch carrier with the sheave holder 2 tighten the clutch carrier nut with the locknut wrench 3 3 Install Clutch housing 1 Spacer Secondary sheave nut 2 TIP While holding the clutch housing with the sheave holder 3 tighten the secondary sheave nut Clutch spring holder 90890 01337 Clutch spring holder arm 90890 01464 2 2 a 1 2 T R Clutch carrier nut 90 Nm 9 0 m kgf 65 ft ...

Page 343: ...when the pulley is at its narrowest position and make sure the V belt is tight 5 Tighten Primary sheave nut 1 TIP While holding the primary fixed sheave with the rotor holding tool 2 tighten the primary sheave nut 6 Install V belt case TIP Make sure that the V belt case gasket lip fits properly around the V belt case Tighten the V belt case bolts in stages and in a crisscross pattern T R Primary s...

Page 344: ...r to ENGINE REMOVAL YP250R on page 5 61 1 Crankshaft position sensor coupler Stator as sembly coupler 1 1 Disconnect 2 Generator cover 1 3 Generator cover gasket 1 4 Dowel pin 2 5 Crankshaft position sensor 1 6 Stator coil 1 7 Oil seal 1 For installation reverse the removal proce dure 4 4 5 6 3 10 2 7 New New New New LS LS 1 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7...

Page 345: ...ts to remove Q ty Remarks 1 Circlip 1 2 Washer 1 3 Starter clutch idle gear shaft 1 4 Starter clutch idle gear 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Starter clutch 1 For installation reverse the removal proce dure E LT 30 Nm 3 0 m kgf 22 ft Ibf T R 80 Nm 8 0 m kgf 58 ft Ibf T R ...

Page 346: ...o protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Make sure the flywheel puller is centered over the generator rotor EAS24560 REMOVING THE STARTER CLUTCH 1 Remove Starter clutch bolts 1 Starter clutch TIP While holding the generator rotor 2 with the sheave holder 3 remove the starter clutch bolts Do not allow ...

Page 347: ...ile holding the generator rotor 2 with the sheave holder 3 tighten the starter clutch bolts Do not allow the sheave holder to touch the projection on the generator rotor EAS24500 INSTALLING THE GENERATOR 1 Install Starter clutch gear Woodruff key Generator rotor Washer Generator rotor nut TIP Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator roto...

Page 348: ...sembly lead grommet 4 Install Oil seal 1 5 Install Generator cover TIP Tighten the generator cover bolts in stages and in a crisscross pattern Yamaha bond No 1215 90890 85505 Three Bond No 1215 Installed depth a 6 0 7 3 mm 0 24 0 29 in T R Generator cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 3 New a 1 New ...

Page 349: ...tarter motor Order Job Parts to remove Q ty Remarks Storage box Air filter case Refer to GENERAL CHASSIS on page 4 1 1 Starter motor lead 1 Disconnect 2 Ground lead 1 Disconnect 3 Starter motor 1 For installation reverse the removal proce dure 2 3 1 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 350: ... 3 Shim 4 Lock washer 1 5 Oil seal 1 6 Bearing 1 7 Starter motor yoke 1 8 Armature assembly 1 9 O ring 1 10 Shim 11 Brush holder set 1 12 Starter motor rear cover 1 13 Bushing 1 For assembly reverse the disassembly pro cedure 1 4 3 8 7 11 9 10 12 2 6 5 13 New New New New New New LS 5 Nm 0 5 m kgf 3 6 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R ...

Page 351: ...sulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the digital circuit tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Limit 22 4 mm 0 88 in Mica undercut d...

Page 352: ...k Bearing Damage wear Replace the bearing EAS24800 ASSEMBLING THE STARTER MOTOR 1 Install Starter motor rear cover 1 Starter motor yoke 2 Starter motor front cover 3 TIP Align the match marks a on the starter motor yoke with the match marks b on the starter mo tor front and rear covers ...

Page 353: ... YP250R on page 5 99 1 Oil baffle plate 1 2 Oil pump assembly 1 3 Oil pump gasket 1 4 Circlip 1 5 Washer 1 6 Oil pump driven gear 1 7 Pin 1 8 Oil pump housing cover 1 9 Pin 2 10 Pin 1 11 Oil pump shaft 1 12 Oil pump inner rotor 1 13 Oil pump outer rotor 1 New New 4 1 5 6 7 9 9 2 8 13 11 14 12 10 3 LS E E M 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 354: ...p housing 1 For installation reverse the removal proce dure Removing the oil pump Order Job Parts to remove Q ty Remarks New New 4 1 5 6 7 9 9 2 8 13 11 14 12 10 3 LS E E M 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 355: ...0 ASSEMBLING THE OIL PUMP 1 Lubricate Inner rotor Outer rotor 2 Lubricate Oil pump shaft with the recommended lubricant 3 Install Oil pump shaft 1 Pin 2 TIP When installing the oil pump shaft align the pin in the oil pump shaft with the groove a in the in ner rotor 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance Less than 0 15 mm 0 0059 in Limit 0 23 mm 0 00...

Page 356: ...on Refer to CHECKING THE OIL PUMP on page 5 110 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly NOTICE ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump assembly bolt 7 Nm 0 7 m kgf 5 1 ft lbf 1 2 a ...

Page 357: ...er to CHANGING THE FINAL TRANS MISSION OIL on page 3 28 Secondary sheave assembly Refer to V BELT AUTOMATIC TRANSMIS SION YP250R on page 5 89 1 Transmission case cover 1 2 Gasket 1 3 Dowel pin 2 4 Primary drive gear 1 5 Washer 2 6 Washer 1 7 1st wheel gear 1 8 Conical spring washer 1 9 Drive axle 1 10 Main axle 1 11 Conical spring washer 1 E E E E E A B LS New 5 3 16 Nm 1 6 m kgf 11 ft Ibf T R E ...

Page 358: ...ION YP250R 5 113 12 Primary driven gear 1 For installation reverse the removal proce dure Removing the transmission Order Job Parts to remove Q ty Remarks E E E E E A B LS New 5 3 16 Nm 1 6 m kgf 11 ft Ibf T R E ...

Page 359: ...iscoloration pitting wear Replace the defective gear s Transmission gear dogs Cracks damage rounded edges Replace the defective gear s 2 Check Transmission gear engagement each pinion gear to its respective wheel gear Incorrect Reassemble the transmission axle assemblies 3 Check Transmission gear movement Rough movement Replace the defective part s EAS37P1066 INSTALLING THE TRANSMISSION 1 Install ...

Page 360: ...0R on page 5 84 Belt drive Refer to V BELT AUTOMATIC TRANSMIS SION YP250R on page 5 89 Oil pump assembly Refer to OIL PUMP YP250R on page 5 108 Transmission Refer to TRANSMISSION YP250R on page 5 112 1 Transmission case breather hose 1 2 Oil strainer cover 1 3 Spring 1 4 Oil strainer 1 5 Breather pipe 1 New New 2 7 11 13 6 1 12 3 4 5 9 9 LS LS E E LS 8 10 New New New LS 10 Nm 1 0 m kgf 7 2 ft Ibf ...

Page 361: ...ain 1 12 Left crankcase 1 13 Oil seal 1 For installation reverse the removal proce dure Removing the crankshaft Order Job Parts to remove Q ty Remarks New New 2 7 11 13 6 1 12 3 4 5 9 9 LS LS E E LS 8 10 New New New LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 20 Nm 2 0 m kgf 14 ft Ibf T R 22 Nm 2 2 m kgf 16 ft Ibf T R 32 Nm 3 2 m kgf 23 ft Ibf T R ...

Page 362: ...ft EAS26020 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove Timing chain 1 TIP Before removing the crankshaft assembly re move the timing chain from the crankshaft sprocket The crankshaft assembly cannot be removed if the timing chain is attached onto the crankshaft sprocket 2 Remove Crankshaft assembly 1 TIP Remove the crankshaft assembly with the crankcase separating tool 2 and M6 bolts 3 Make sure th...

Page 363: ... 2 Measure Big end side clearance Out of specification Replace the crank shaft 3 Measure Crankshaft width Out of specification Replace the crank shaft 4 Check Crankshaft sprocket 1 Damage wear Replace the crankshaft Bearings 2 Cracks damage wear Replace the crank shaft Oil pump drive gear 3 Damage wear Replace the crankshaft 5 Check Crankshaft journal Scratches wear Replace the crankshaft Cranksha...

Page 364: ...ANKSHAFT 1 Lubricate Oil seals Bearings Oil pump drive gear 2 Install Oil seal 1 to the left crankcase 3 Install Timing chain 1 TIP Install the timing chain so it is not visible through the opening a in the left crankcase 2 4 Install Crankshaft assembly 1 to the left crankcase TIP Install the crankshaft assembly with the crank shaft installer pot 2 crankshaft installer bolt 3 adapter 4 and spacer ...

Page 365: ...ating surfaces 2 Apply Sealant onto the crankcase mating surfaces TIP Do not allow any sealant to come into contact with the oil gallery 3 Install Right crankcase 1 TIP Install the crankshaft assembly with the crank shaft installer pot 2 crankshaft installer bolt 3 adapter 4 and spacer 5 4 Install Water pump assembly Crankcase bolts TIP Tighten the crankcase bolts in stages and in a crisscross pat...

Page 366: ...CRANKSHAFT YP250R 5 121 ...

Page 367: ...HE WATER PUMP 6 6 CHECKING THE WATER PUMP 6 6 ASSEMBLING THE WATER PUMP 6 6 INSTALLING THE WATER PUMP 6 7 RADIATOR YP250R 6 8 CHECKING THE RADIATOR 6 9 INSTALLING THE RADIATOR 6 9 THERMOSTAT YP250R 6 10 CHECKING THE THERMOSTAT 6 11 INSTALLING THE THERMOSTAT 6 11 WATER PUMP YP250R 6 12 DISASSEMBLING THE WATER PUMP 6 14 CHECKING THE WATER PUMP 6 14 ASSEMBLING THE WATER PUMP 6 14 INSTALLING THE WATER...

Page 368: ...NG THE COOLANT on page 3 18 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator filler hose 1 5 Radiator inlet hose 1 6 Radiator outlet hose 1 7 Radiator fan motor coupler 1 Disconnect 8 Radiator 1 9 Radiator fan motor 1 For installation reverse the removal proce dure 3 3 9 7 3 2 3 8 4 1 6 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft...

Page 369: ...e 3 Check Radiator fan motor Damage Replace Malfunction Check and repair Refer to CHECKING THE RADIATOR FAN MOTOR on page 8 87 EAS37P1107 INSTALLING THE RADIATOR 1 Install Radiator outlet hose screw clamp 1 TIP Install the radiator outlet hose screw clamp in the position shown in the illustration 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOL...

Page 370: ...ty Remarks Storage box Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 18 1 Radiator inlet hose 1 Disconnect 2 Thermostat inlet hose 1 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal proce dure New 3 2 4 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R ...

Page 371: ...re TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS37P1110 INSTALLING THE THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather hole a in the position shown in the illustration 2 Fill Cooling system with the specified amount of the recom mended c...

Page 372: ...3 Water pump housing cover 1 4 Water pump housing cover gasket 1 5 Cylinder head breather hose 1 Disconnect 6 Water pump housing 1 7 Water pump housing plate 1 1 8 Water pump housing plate 2 1 9 Water pump housing plate gasket 1 10 Impeller shaft 1 11 Water pump seal 1 12 Bearing 1 For installation reverse the removal proce dure 2 3 4 11 10 6 5 7 8 9 12 1 LT 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 ...

Page 373: ...TER PUMP 1 Install Water pump seal 1 into the water pump housing 2 TIP Install the water pump seal with the special tools to the specified depth as shown in the illustra tion 2 Lubricate Water pump seal 3 Install Impeller shaft Water pump housing plate gasket 1 Water pump housing plate 2 2 1 2 2 1 New Installed depth of water pump seal 0 0 5 mm 0 0 02 in Mechanical seal installer 90890 04145 Middl...

Page 374: ...R PUMP 1 Install O rings Water pump assembly 1 TIP Lubricate the O rings with a thin coat of lithium soap based grease Align the projection a on the impeller shaft with the slot b in the camshaft sprocket bolt 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 18 3 Check Cooling system Leaks Repair or replace any faulty part T R Wate...

Page 375: ...G THE COOLANT on page 3 32 1 Radiator cap 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Radiator filler hose 1 5 Radiator inlet hose 1 6 Radiator outlet hose 1 7 Radiator fan motor coupler 1 Disconnect 8 Radiator 1 9 Radiator fan motor 1 For installation reverse the removal proce dure 3 3 9 7 3 2 3 8 4 1 6 5 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft ...

Page 376: ...e 3 Check Radiator fan motor Damage Replace Malfunction Check and repair Refer to CHECKING THE RADIATOR FAN MOTOR on page 8 87 EAS26400 INSTALLING THE RADIATOR 1 Install Radiator outlet hose screw clamp 1 TIP Install the radiator outlet hose screw clamp in the position shown in the illustration 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLAN...

Page 377: ...age box Refer to GENERAL CHASSIS on page 4 1 Coolant Drain Refer to CHANGING THE COOLANT on page 3 32 1 Radiator inlet hose 1 Disconnect 2 Thermostat inlet hose 1 3 Thermostat cover 1 4 Thermostat 1 For installation reverse the removal proce dure New 10 Nm 1 0 m kgf 7 2 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf T R 2 1 4 3 ...

Page 378: ...ure TIP If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Cracks damage Replace EAS26460 INSTALLING THE THERMOSTAT 1 Install Thermostat TIP Install the thermostat with its breather hole a in the position shown in the illustration 2 Fill Cooling system with the specified amount of the recom mended co...

Page 379: ...or rotor Refer to STARTER CLUTCH AND GENER ATOR YP250R on page 5 99 Coolant Drain Refer to CHANGING THE COOLANT on page 3 32 1 Oil baffle plate 1 2 Impeller shaft gear 1 3 Washer 1 4 Radiator outlet hose 1 Disconnect 5 Water pump outlet pipe 1 6 Water pump housing cover 1 7 Gasket 1 8 Water pump housing 1 New LS LS 12 11 13 New New New 7 8 10 9 5 6 4 3 2 1 LS LS A LT M 10 Nm 1 0 m kgf 7 2 ft Ibf T...

Page 380: ...Oil seal 1 For installation reverse the removal proce dure Removing the water pump Order Job Parts to remove Q ty Remarks New LS LS 12 11 13 New New New 7 8 10 9 5 6 4 3 2 1 LS LS A LT M 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 381: ... 1 Check Water pump housing cover Water pump housing Impeller shaft Cracks damage wear Replace 2 Check Bearing Rough movement Replace EAS26570 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket that matches its outside diameter 2 Install Water pump seal 1 ...

Page 382: ...tall Impeller shaft gear 1 TIP Align the slot on the impeller shaft with the pro jection on the impeller shaft gear when installing 2 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 32 3 Check Cooling system Leaks Repair or replace any faulty part Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A Middle driv...

Page 383: ... 7 5 REMOVING THE FUEL HOSE 7 9 CHECKING THE FUEL INJECTOR 7 9 CHECKING THE THROTTLE BODY 7 9 INSTALLING THE INTAKE MANIFOLD YP125R 7 9 INSTALLING THE INTAKE MANIFOLD YP250R 7 9 INSTALLING THE FUEL HOSE 7 10 INSTALLING THE THROTTLE BODY 7 10 CHECKING THE THROTTLE POSITION SENSOR 7 10 CHECKING THE ISC IDLE SPEED CONTROL UNIT 7 10 ...

Page 384: ...1 6 Plastic locking tie 1 YP250R only 7 Tube 1 YP250R only 8 Fuel hose connector cover 1 9 Fuel hose 1 Disconnect 10 Fuel sender 1 11 Fuel tank bracket 1 12 Radiator fan motor coupler 1 Disconnect 13 Clamp 3 14 Radiator cap holder bolt 1 New New LT 16 13 13 14 12 16 1 15 11 4 4 10 8 9 3 7 6 2 5 17 4 13 Nm 1 3 m kgf 9 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 ...

Page 385: ...the fuel tank Order Job Parts to remove Q ty Remarks New New LT 16 13 13 14 12 16 1 15 11 4 4 10 8 9 3 7 6 2 5 17 4 13 Nm 1 3 m kgf 9 4 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 7 Nm 0 7 m kgf 5 1 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R 14 Nm 1 4 m kgf 10 ft Ibf T R ...

Page 386: ...under where it will be removed 4 Remove Fuel sender 1 TIP Remove the fuel sender with the fuel sender wrench 2 5 Remove Fuel tank TIP To remove the fuel tank lower the radiator 1 NOTICE ECA37P1021 When removing the fuel tank be sure not to pull forcefully on the radiator hoses 2 EAS37P1071 CHECKING THE FUEL PRESSURE 1 Check Pressure regulator operation a Remove the fuel hose connector cover 1 and ...

Page 387: ...hose connector cover NOTICE ECA37P1022 When installing the fuel hose make sure that it is securely connected and that the fuel hose connector cover is in the correct posi tion otherwise the fuel hose will not be prop erly installed TIP Wipe up any fuel remaining in the recess a in the fuel pump with a dry rag 1 After installing the fuel hose connector cover 2 make sure that it is installed securel...

Page 388: ...ler 1 Disconnect 7 Throttle position sensor 1 8 Throttle cable 2 Disconnect 9 Air filter case joint clamp screw 1 Loosen 10 Throttle body joint clamp screw 1 Loosen 11 Throttle body 1 12 Fuel injector coupler 1 Disconnect 13 Fuel hose connector cover 1 14 Fuel injector assembly 1 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf ...

Page 389: ...ts to remove Q ty Remarks 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R 1 5 Nm 0 15 m kgf 1 1 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R New 2 New New LS 3 1 4 16 15 13 12 14 5 11 7 6 10 9 8 LS E ...

Page 390: ... Throttle position sensor 1 8 Throttle cable 2 Disconnect 9 Breather hose air filter case to throttle body 1 10 Air filter case joint clamp screw 1 Loosen 11 Throttle body joint clamp screw 1 Loosen 12 Throttle body 1 13 Fuel injector coupler 1 Disconnect 14 Fuel hose connector cover 1 15 Fuel injector assembly 1 16 Intake manifold 1 12 3 4 1 9 5 10 16 13 8 8 17 15 11 7 6 14 2 LS New New New E LS ...

Page 391: ...P250R Order Job Parts to remove Q ty Remarks 12 3 4 1 9 5 10 16 13 8 8 17 15 11 7 6 14 2 LS New New New E LS 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 10 Nm 1 0 m kgf 7 2 ft Ibf T R 2 Nm 0 2 m kgf 1 4 ft Ibf T R 3 Nm 0 3 m kgf 2 2 ft Ibf T R 5 Nm 0 5 m kgf 3 6 ft Ibf T R 12 Nm 1 2 m kgf 8 7 ft Ibf T R ...

Page 392: ...e EAS26990 CHECKING THE THROTTLE BODY 1 Check Throttle body Cracks damage Replace the throttle body 2 Check Fuel passages Obstructions Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with compressed air 3 Check YP250R only Piston valve Damage scratches wear Replace Piston valve diaphragm Cracks tears Rep...

Page 393: ...maining in the recess a in the fuel pump with a dry rag 1 After installing the fuel hose connector cover 2 make sure that it is installed securely EAS37P1076 INSTALLING THE THROTTLE BODY 1 Install Throttle body TIP Align the projection a on the throttle body with the slot b in the throttle body joint EAS37P1077 CHECKING THE THROTTLE POSITION SENSOR 1 Check Throttle position sensor Refer to CHECKIN...

Page 394: ...THROTTLE BODY 7 11 ...

Page 395: ...RCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 29 FUEL INJECTION SYSTEM 8 31 CIRCUIT DIAGRAM 8 31 ECU SELF DIAGNOSTIC FUNCTION 8 33 TROUBLESHOOTING METHOD 8 34 DIAGNOSTIC MODE 8 34 TROUBLESHOOTING DETAILS 8 36 DIAGNOSTIC CODE TABLE 8 54 FUEL PUMP SYSTEM 8 57 CIRCUIT DIAGRAM 8 57 TROUBLESHOOTING 8 59 IMMOBILIZER SYSTEM 8 61 CIRCUIT DIAGRAM 8 61 GE...

Page 396: ... 84 CHECKING THE STARTER MOTOR OPERATION 8 84 CHECKING THE STATOR COIL 8 85 CHECKING THE RECTIFIER REGULATOR 8 85 CHECKING THE HORN 8 85 CHECKING THE FUEL SENDER 8 86 CHECKING THE FUEL LEVEL WARNING LIGHT 8 86 CHECKING THE SPEED SENSOR 8 87 CHECKING THE RADIATOR FAN MOTOR 8 87 CHECKING THE COOLANT TEMPERATURE SENSOR 8 87 CHECKING THE THROTTLE POSITION SENSOR 8 88 CHECKING THE INTAKE AIR PRESSURE S...

Page 397: ......

Page 398: ...g R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B B B...

Page 399: ...EM 8 2 2 Crankshaft position sensor 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 18 Sidestand switch 29 Lean angle sensor 31 ECU engine control unit 32 Ignition coil 33 Spark plug ...

Page 400: ...n page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 24 Re gap or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 83 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 82 Replace the spark plug cap 6 Check the ig...

Page 401: ...k the sidestand switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the sidestand switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 84 Replace the lean angle sensor 11 Check the entire ignition system wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or repair the ignition sys tem wiring Replace the ECU ...

Page 402: ...B1 Sb Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B B...

Page 403: ...Ignition fuse 11 Signaling system fuse 12 Battery 13 Main fuse 14 Starter relay 15 Starter motor 16 Diode 17 Frame ground 18 Sidestand switch 20 Starting circuit cut off relay 22 Start switch 24 Front brake light switch 46 Rear brake light switch ...

Page 404: ...losed and the sidestand is up the sidestand switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these condi tions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cut off relay is closed and the engin...

Page 405: ...ttery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Starting circuit cut off relay 6 Sidestand switch 7 Signaling system fuse 8 Front brake light switch 9 Rear brake light switch 10 Start switch 11 Diode 12 Starter relay 13 Starter motor ...

Page 406: ...ry 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 8 84 Starter motor is OK Perform the electric starting system troubleshooting starting with step 5 4 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 46 and CHECKING THE STARTER MO TOR on page 5 106 Repair or replace the starter motor 5 Check the starting circuit cut off re lay Refer...

Page 407: ...ront and rear Refer to CHECKING THE SWITCHES on page 8 73 Replace the brake light switch es 10 Check the start switch Refer to CHECKING THE SWITCHES on page 8 73 The start switch is faulty Replace the right handlebar switch 11 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or repair the starting sys tem wiring The starting system circuit is OK ...

Page 408: ...W W W W2 W3 R W Gy B W R R L R B G L Y L B W L W Dg W Y Br Br W Ch G Y Dg Br Ch G Y L W Br W W Y R W3 W2 W B L W BLACK B R ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br LBr R R R G R W R B R Y R Br R Br R2 Br L Br L Br L Br R R W R R B B B R B L W B R L W L W W Y Dg Ch Br W B R B L Y L R R B B B Gy B 11 12 13 15 16 17 18 19 21 22 23 1 2 3 4 5 6 7 8 9 10 14 ...

Page 409: ...CHARGING SYSTEM 8 12 1 AC magneto 3 Rectifier regulator 12 Battery 13 Main fuse 17 Frame ground ...

Page 410: ... AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 85 Replace the crankshaft position sen sor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 85 Replace the rectifier regulator 5 Check the entire charging system wiring Refer to CIR...

Page 411: ...CHARGING SYSTEM 8 14 ...

Page 412: ...g R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B B B...

Page 413: ...fuse 10 Headlight fuse 11 Signaling system fuse 12 Battery 13 Main fuse 17 Frame ground 31 ECU engine control unit 40 Headlight relay 42 Dimmer switch 43 Pass switch 49 Tail brake light 55 Headlight 56 Auxiliary light 57 License plate light 68 Meter light 69 High beam indicator light ...

Page 414: ...al hazard and signaling sys tem Refer to CHECKING THE FUS ES on page 8 77 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 5 Check the dimmer switch Refer to CHECKING THE SWITCHES on pa...

Page 415: ...LIGHTING SYSTEM 8 18 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 8 15 Properly connect or repair the lighting sys tem wiring Replace the ECU or meter assembly ...

Page 416: ...Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B B ...

Page 417: ...ard relay 44 Turn signal switch 45 Horn switch 46 Rear brake light switch 48 Right rear turn signal light 49 Tail brake light 51 Left rear turn signal light 52 Right front turn signal light 53 Left front turn signal light 58 Fuel sender 59 V belt replacement indicator reset coupler 62 Multifunction meter 63 Speedometer 64 Tachometer 65 Engine oil change indicator 66 V belt replacement indicator 70...

Page 418: ...the fuses Main signaling system ignition ECU and turn signal hazard Refer to CHECKING THE FUS ES on page 8 77 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 4 Check the entire signali...

Page 419: ...Refer to CHECKING THE BULBS AND BULB SOCKETS on page 8 76 Replace the tail brake light bulb socket or both 2 Check the front brake light switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the front brake light switch 3 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the rear brake light switch 4 Check the entire signaling system wiring Refer to CIRCUIT...

Page 420: ...Check the turn signal hazard relay Refer to CHECKING THE TURN SIGNAL HAZARD RELAY on page 8 81 Replace the turn signal hazard relay 5 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 86 Replace the fuel sender 2 Check th...

Page 421: ...nsor 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the ECU or meter assembly 1 Check the crankshaft position sen sor Refer to CHECKING THE CRANK SHAFT POSITION SENSOR on page 8 83 Replace the crankshaft position sen sor stator assembly 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRA...

Page 422: ...heck the V belt replacement indi cator reset coupler Refer to CHECKING THE V BELT REPLACEMENT INDICATOR RE SET COUPLER on page 8 90 Replace the V belt replacement indicator reset coupler 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or repair the signaling system wiring Replace the meter assembly 1 Check the entire signaling system wiring Refer t...

Page 423: ...SIGNALING SYSTEM 8 26 ...

Page 424: ... R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B B B ...

Page 425: ... 28 5 Main switch 6 ECU fuse 7 Radiator fan motor fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 25 Coolant temperature sensor 31 ECU engine control unit 73 Radiator fan motor 74 Radiator fan motor relay ...

Page 426: ...e or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 87 Replace the radiator fan motor 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 80 Replace the radiator fan motor relay 6 Check the coolant temperature ...

Page 427: ...COOLING SYSTEM 8 30 ...

Page 428: ...1 Sb Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B...

Page 429: ...uel pump 25 Coolant temperature sensor 26 Throttle position sensor 27 Intake air pressure sensor 28 Intake air temperature sensor 29 Lean angle sensor 30 Speed sensor 31 ECU engine control unit 32 Ignition coil 33 Spark plug 34 Fuel injector 35 O2 sensor 36 ISC idle speed control unit 40 Headlight relay 62 Multifunction meter 67 Engine trouble warning light 73 Radiator fan motor 74 Radiator fan mo...

Page 430: ...listed below is present and the start switch is pushed Checking for a defective engine trouble warning light The engine trouble warning light comes on for 2 0 seconds after the main switch has been set to ON and when the start switch is being pushed If the warning light does not come on under these conditions the warning light bulb may be defective ECU detects an abnormal signal from a sensor If t...

Page 431: ...diagnos tic mode Refer to DIAGNOSTIC CODE TA BLE on page 8 54 Diagnostic code No 62 TIP Setting the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of the following sensors and actuators in the Diagnostic mode Refer to TROUBLESHOOTING DETAILS on page 8 36 If a malfunction is det...

Page 432: ...selected diagnostic code number press the DOWN button Press the DOWN but ton for 1 second or longer to automatically decrease the diagnostic code numbers To increase the selected diagnostic code number press the UP button Press the UP button for 1 second or longer to automatically increase the diagnostic code numbers 6 Check the operation of the sensor or actuator Sensor operation The data represe...

Page 433: ...4 Fault code No 12 Item Crankshaft position sensor no normal signals are received from the crankshaft position sensor Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No FI diagnostic tool display Checking method Probable cause of malfunction Check or maintenance job 1 Installed condition of crankshaft position sensor Check for looseness or pinching 2 Connections Cra...

Page 434: ...e sensor coupler and ECU coupler gray red gray red pink white pink white gray black gray black 3 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 Replace if defective Refer to CHECKING THE INTAKE AIR PRESSURE SENSOR on page 8 88 Reinstatement method Turning the main switch to ON Fault code No 14 Item Intake air pressure sensor hose line malfunction clogged or detached ho...

Page 435: ...lly closed Check with throttle fully opened Probable cause of malfunction Check or maintenance job 1 Installed condition of throttle position sensor Check for looseness or pinching Check that the sensor is installed in the speci fied position 2 Connections Throttle position sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of ...

Page 436: ...SENSOR on page 8 88 Reinstatement method Turning the main switch to ON Fault code No 19 Item Sidestand switch a break or disconnection of the blue yellow lead of the ECU is detected Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No 20 FI diagnostic tool display Sidestand switch ON stand retracted OFF stand extended Checking method Extend and retract the sidestand P...

Page 437: ...nction repair it and connect the coupler securely 3 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between coolant temperature sensor coupler and ECU coupler green red green red gray black gray black 4 Defective coolant temperature sensor Execute the diagnostic mode Code No 06 Replace if defective Refer to CHECKING THE COOLANT TEM PERATURE SENSOR on pa...

Page 438: ...ch to ON Fault code No 24 Item O2 sensor no normal signal is received from the O2 sensor Fail safe system Able to start engine Able to drive vehicle Diagnostic code No FI diagnostic tool display Checking method Probable cause of malfunction Check or maintenance job 1 Installed condition of O2 sensor Check for looseness or pinching 2 Connections O2 sensor coupler Wire harness ECU coupler Check the ...

Page 439: ...sor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 4 Defective lean angle sensor Execute the diagnostic mode Code No 08 Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 84 Reinstatement method Turning the main switch to ON how...

Page 440: ... The amount of air fuel ratio feedback compensa tion is maintained continuously in the vicinity of the lower lim it Fail safe system Able to start engine Able to drive vehicle Diagnostic code No FI diagnostic tool display Checking method Probable cause of malfunction Check or maintenance job 1 Installed condition of O2 sensor Check for looseness or pinching 2 Connections O2 sensor coupler Wire har...

Page 441: ...tenance job 1 Connections Ignition coil connector primary coil side Wire harness ECU coupler Check the connector and coupler for any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler or connector securely 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Betwe...

Page 442: ...d by the ECU Check that the ISC unit coupler is not discon nected The ISC valve is stuck fully open if it does not operate when the main switch is turned OFF Touch the ISC unit with your hand and check if it is vibrating to confirm if the ISC valve is op erating 3 ISC valve is not moving correctly Execute the diagnostic mode Code No 54 After the ISC valve is fully closed it opens to the standby op...

Page 443: ...nable to start engine Unable to drive vehicle Diagnostic code No 08 FI diagnostic tool display Lean angle sensor 0 4 1 4 upright 3 7 4 4 overturned Checking method Remove the lean angle sensor and incline it more than 45 de grees Probable cause of malfunction Check or maintenance job 1 Connections Lean angle sensor coupler Wire harness ECU coupler Check the coupler for any pins that may be pulled ...

Page 444: ...if there is an open or short circuit Between speed sensor coupler and ECU cou pler gray red gray red gray gray gray black gray black 3 Defective speed sensor Execute the diagnostic mode Code No 07 Replace if defective Refer to CHECKING THE SPEED SENSOR on page 8 87 4 This fault code will appear on the multi function display if the vehicle speed is less than 2 km h the throttle is opened 70 degrees...

Page 445: ... Between ignition fuse terminal and ECU cou pler red black red black 3 Malfunction or open circuit in fuel sys tem Execute the diagnostic mode Code No 09 Reinstatement method Starting the engine and operating it at idle Fault code No 44 Item EEPROM fault code No an error is detected while reading or writing on EEPROM CO adjustment value Fail safe system Able to start engine Able to drive vehicle D...

Page 446: ...egulator Replace if defective Refer to CHARGING SYSTEM on page 8 11 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between battery terminal and ECU fuse termi nal red red Between ECU fuse terminal and ECU coupler red green red green Reinstatement method Starting the engine and operating it at idle Fault code No 50 Item Faulty ECU memory When this mal...

Page 447: ...ely 2 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Between ISC idle speed control unit and ECU coupler pink pink light green light green green green sky blue sky blue 3 Defective ISC idle speed control unit Execute the diagnostic mode Code No 54 Replace if defective Refer to THROTTLE BODY on page 7 5 Reinstatement method Turning the main switch to ON...

Page 448: ...ter display Checking method Probable cause of malfunction Check or maintenance job 1 Connections Meter assembly coupler Wire harness ECU coupler Self diagnosis signal coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler securely 2 Open or short circuit in wire harness Repair or replace i...

Page 449: ...t Between meter assembly coupler and self di agnosis signal coupler yellow blue yellow blue Between self diagnosis signal coupler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Reinstatement method Turning the main switch to ON Fault code No Er 4 Item ECU internal malfunction input signal error non registered ...

Page 450: ...l coupler yellow blue yellow blue Between self diagnosis signal coupler and ECU coupler yellow blue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Reinstatement method Turning the main switch to ON Fault code No Er 4 Item ECU internal malfunction input signal error non registered data has been received from the meter ...

Page 451: ...actuates five times by listening for the operating sound 52 Headlight relay Actuates the headlight relay for five cycles of five sec onds ON 2 seconds OFF 3 seconds Illuminates the WARNING LED on the FI diagnostic tool the engine trouble warn ing light and headlight Check that the headlight re lay actuates five times by listening for the operating sound 61 Malfunction history code display No histo...

Page 452: ...connection in connecting lead The main switch is set to OFF Malfunction in FI diagnostic tool Malfunction in ECU ERROR 4 Commands from the FI diagnostic tool are not accepted by the ECU Set the main switch to OFF once and then set the FI diagnostic tool to the CO adjustment mode or the diagnostic mode Vehicle battery is insufficiently charged Malfunction in FI diagnostic tool Malfunction in ECU ...

Page 453: ...FUEL INJECTION SYSTEM 8 56 ...

Page 454: ...Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B B ...

Page 455: ...FUEL PUMP SYSTEM 8 58 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 19 Fuel pump 31 ECU engine control unit ...

Page 456: ... the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 78 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 4 Check the fuel pump operation Refer to CHECKING THE FUEL PRESSURE on page 7 3 Replace the fuel tank with fuel pump 5 Check the entire fuel pump system wiring Re...

Page 457: ...FUEL PUMP SYSTEM 8 60 ...

Page 458: ...b Lg R G R B G B B2 Gy Y G Br W L G P G R Gy B Y G Gy R R G Br B Y L B Sb Ch Dg Y Br R L R B Sb G L Y L B L Gy B Y Gy R Gy B BLACK A ON OFF OPEN LOCK P W R W W2 W2 W3 W3 R L Br L R B B W Y L R L G L G L R L R B Y L Y L Y L B L L G B R W L B L B G Y R Y Br W Br R2 Br W Br Br B P P G Y Br B W B R Y R Y2 R B B W R L Br Y Dg Ch Sb B B B B B B Br Br Ch Ch Dg G Y G Y Dg Dg Ch Br Br G Y Gy Gy Sb B L B B ...

Page 459: ...er unit and meter assembly 5 Main switch 6 ECU fuse 9 Ignition fuse 12 Battery 13 Main fuse 17 Frame ground 31 ECU engine control unit 61 Immobilizer system indicator light 62 Multifunction meter 75 Self diagnosis signal coupler 76 Immobilizer unit ...

Page 460: ... is lost regis tering new codes in the standard keys is impossible The standard keys can still be used to start the vehicle However if code re registering is required e g if a new standard key is made or all keys are lost the entire immobilizer system must be replaced Therefore it is highly rec ommended to use either standard key for driving and to keep the code re registering key in a safe place ...

Page 461: ...tandby mode To enable the immobilizer system turn the ignition key to OFF 30 seconds later the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours After that time the indicator light will stop flashing but the immobilizer system is still enabled Parts to be replaced Key registration re quirement Main switch immo bilizer unit Standard key ECU Acc...

Page 462: ...ch then turn the key to ON within 5 seconds to activate the key registration mode TIP The existing standard key code is erased from the memory when the key registration mode is activated When the key registration mode is activated the immobilizer system indicator light flashes rapidly 4 While the indicator light is flashing turn the main switch to OFF remove the key and within 5 sec onds insert th...

Page 463: ... Main switch OFF c LED on d LED off e Less than 5 0 s f Code re registering key g First standard key h Second standard key i Registration mode A Registration of the second standard key is complete B Immobilizer system indicator light stops flashing when the registration of the second standard key is complete a Main switch ON b Main switch OFF c LED on d LED off e Less than 5 0 s f Code re register...

Page 464: ...lean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 73 Replace the main switch immobilizer unit 4 Check the entire immobilizer sys tem wiring Refer to CIRCUIT DIAGRAM on page 8 61 Properly connect or repair the immobilizer system wiring Check the condition each of the im mobilizer system circuits Refer to SELF DIAGNOSIS FAULT ...

Page 465: ...nit mal function 4 ECU malfunction 1 Check the wire harness and connector 2 Replace the main switch im mobilizer unit 3 Replace the ECU 54 IMMOBILIZER UNIT Codes transmitted between the ECU and the immobilizer unit do not match Noise interference or disconnected lead ca ble 1 Interference due to radio wave noise 2 Disconnected com munication harness 3 Immobilizer unit mal function 4 ECU failure Th...

Page 466: ...IMMOBILIZER SYSTEM 8 69 a Light on b Light off ...

Page 467: ...IMMOBILIZER SYSTEM 8 70 ...

Page 468: ...ELECTRICAL COMPONENTS 8 71 EAS27970 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 22 23 24 25 26 28 29 30 27 21 14 ...

Page 469: ...ature sensor 11 Intake air pressure sensor 12 Throttle position sensor 13 ISC idle speed control unit 14 Crankshaft position sensor 15 Stator coil 16 Coolant temperature sensor 17 O2 sensor 18 Sidestand switch 19 Starter relay 20 Main fuse 21 Headlight relay 22 Radiator fan motor 23 Horn 24 Starting circuit cut off relay 25 Speed sensor 26 Rectifier regulator 27 Radiator fan motor relay 28 Diode 2...

Page 470: ...3 EAS27980 CHECKING THE SWITCHES 1 2 3 4 Br W Ch Dg P B B B BLUE 10 5 7 6 8 9 Br G Y ON R Br L Br R OFF OPEN LOCK P Br R R Br L G Y Br R Y L B B P Dg Y G Br W Ch L B G Y R Y Y Dg Ch Br W G Y Br L W W Y L W Dg W Y Br Br W Ch G Y ...

Page 471: ...TRICAL COMPONENTS 8 74 1 Start switch 2 Hazard switch 3 Front brake light switch 4 Main switch 5 Dimmer switch 6 Pass switch 7 Turn signal switch 8 Horn switch 9 Rear brake light switch 10 Sidestand switch ...

Page 472: ...er to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed circuit between switch terminals a...

Page 473: ...bs 1 Remove Bulb WARNING EWA37P1018 Since headlight bulbs get extremely hot keep flammable products and your hands away from them until they have cooled down NOTICE ECA37P1039 Be sure to hold the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwis...

Page 474: ... behind the front cowling assembly NOTICE ECA37P1040 To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove Upper panel and or front cowling assembly Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity TIP Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the f...

Page 475: ...EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion NOTICE ECA13661 This is a VRLA Valve Regulated Lead Acid battery Never remove the sealing caps be cause the balance between cells will not be maintained an...

Page 476: ...e removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded bat tery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during...

Page 477: ... battery unused for more than 30 minutes 6 Install Battery 7 Connect Battery leads to the battery terminals NOTICE ECA13630 First connect the positive battery lead 1 and then the negative battery lead 2 8 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Install Upper panel Refer to GENERAL CHASSIS on page 4 1 EAS28040 CHECKING THE RELAYS Check each switch fo...

Page 478: ... tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal W Y L Y G Y R B 1 2 4 3 R R L W R B 1 2 4 3 R Y L B R Y W B 1 2 3 4 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positi...

Page 479: ...1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the pocket tester Ω 1 to the igni tion coil as shown Turn signal hazard relay output voltage DC 12 V Pocket tester 90890 03112 Analog pocket tes...

Page 480: ...own c Set the main switch to ON d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance Out of specification Replace the crank shaft position sensor...

Page 481: ...oting starting with step 4 Refer to TROUBLESHOOTING on page 8 9 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicini...

Page 482: ...ximate ly 5000 r min d Measure the charging voltage EAS28180 CHECKING THE HORN 1 Check Horn resistance Out of specification Replace a Disconnect the horn connectors from the horn terminals b Connect the pocket tester Ω 1 to the horn terminals Stator coil resistance 0 28 0 42 Ω at 20 C 68 F YP125R 0 32 0 48 Ω at 20 C 68 F YP250R Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tes...

Page 483: ...The warning light comes on for a few sec onds then goes off The warning light is OK The warning light does not come on Re place the meter assembly All LCD segments of the fuel meter 2 and the fuel level warning light 1 flash open or short circuit detected in fuel sender Re place the fuel sender Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe horn terminal 1 Negative...

Page 484: ...on page 5 7 and CYLINDER HEAD YP250R on page 5 67 WARNING EWA14130 Handle the coolant temperature sensor with special care Never subject the coolant temperature sen sor to strong shocks If the coolant temper ature sensor is dropped replace it 2 Check Coolant temperature sensor resistance Out of specification Replace a Connect the pocket tester Ω 1k 100 to the coolant temperature sensor terminals a...

Page 485: ...lace the throttle position sen sor Out of specification closed position Re place the throttle position sensor EAS28410 CHECKING THE INTAKE AIR PRESSURE SENSOR 1 Check Intake air pressure sensor output voltage Out of specification Replace a Connect the test harness between the intake air pressure sensor and wire harness b Connect the pocket tester DC 20 V to the test harness T R Coolant temperature...

Page 486: ...t get wet c Place a thermometer 3 in the water d Heat the water or let it cool down to the spec ified temperature e Measure the intake air temperature sensor resistance EAS37P1083 CHECKING THE AIR TEMPERATURE SENSOR 1 Remove Air temperature sensor WARNING EWA37P1017 Handle the air temperature sensor with special care Never subject the air temperature sensor to strong shocks If the air temperature ...

Page 487: ... c Measure the ISC unit resistance Out of specification Replace the throttle body EAS37P1084 CHECKING THE V BELT REPLACEMENT INDICATOR RESET COUPLER 1 Remove V belt replacement indicator reset coupler 2 Check V belt replacement indicator reset coupler Out of specification Replace the V belt re placement indicator coupler Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester 90890...

Page 488: ... 91 a Connect the pocket tester Ω 1 to the V belt replacement indicator reset coupler ter minals b Check the V belt replacement indicator reset coupler for continuity Pocket tester 90890 03112 Analog pocket tester YU 03112 C ...

Page 489: ... FAILURE HARD STARTING 9 1 INCORRECT ENGINE IDLING SPEED 9 1 POOR MEDIUM AND HIGH SPEED PERFORMANCE 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 2 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY FRONT FORK LEGS 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 3 ...

Page 490: ... damaged fuel hose 2 Fuel pump Faulty fuel pump Clogged fuel pump filter 3 Throttle body Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insu...

Page 491: ...rimary sliding sheave Seized primary sliding sheave Poor starting performance 1 V belt V belt slips Oil or grease on the V belt 2 Primary sliding sheave Faulty operation 3 Clutch shoe s Bent damaged or worn clutch shoe Poor speed performance 1 V belt Oil or grease on the V belt 2 Primary pulley weight s Faulty operation Worn primary pulley weight 3 Primary fixed sheave Worn primary fixed sheave 4 ...

Page 492: ...EAS28670 UNSTABLE HANDLING 1 Handlebar Bent or improperly installed handlebar 2 Steering head components Improperly installed lower handlebar holder Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race 3 Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring both front fork legs Broken fork spring B...

Page 493: ... relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse Turn signals flash slowly Faulty turn signal hazard relay Faulty main switch Faulty turn signal switch Incorrect turn signal bulb Turn signals remain lit Faulty turn signal hazard relay Burnt out turn signal bulb Turn signals flash quickly...

Page 494: ...ght assembly 51 Left rear turn signal light 52 Right front turn signal light 53 Left front turn signal light 54 Headlight assembly 55 Headlight 56 Auxiliary light 57 License plate light 58 Fuel sender 59 V belt replacement indicator re set coupler 60 Meter assembly 61 Immobilizer system indicator light 62 Multifunction meter 63 Speedometer 64 Tachometer 65 Engine oil change indicator 66 V belt rep...

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Page 496: ...YAMAHA MOTOR ESPAÑA S A ...

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